Exhaust Manifold and Three Way Catalyst
EXHAUST MANIFOLD AND THREE WAY CATALYSTComponents:
Removal and Installation
REMOVAL
WARNING: Perform the work when the exhaust and cooling system have completely cooled down.
1. Remove engine room cover (RH and LH).
2. Remove engine cover with power tool.
3. Remove air duct (inlet), air cleaner case and air duct and resonator assembly.
4. Remove front and rear engine undercovers with power tool.
5. Drain engine coolant from radiator.
CAUTION:
^ Perform this step when engine is cold.
^ Do not spill engine coolant on drive belts.
6. Remove radiator.
7. Remove drive belts.
8. Remove exhaust front tube with power tool.
9. Remove air fuel ratio sensor 1 as follows:
a. Disconnect harness connector of each air fuel ratio sensor 1.
b. Remove air fuel ratio sensor 1 on both bank with heated oxygen sensor wrench (SST).
CAUTION:
^ Be careful not to damage air fuel ratio sensor 1.
^ Discard any air fuel ratio sensor 1 which has been dropped from a height of more than 0.5 m (19.7 inch) onto a hard surface such as a concrete floor; replace with a new one.
10. Remove exhaust manifold and three way catalyst (left bank) as follows.
a. Disconnect A/C piping from A/C compressor, then remove A/C compressor with power tool.
b. Remove steering lower joint to enable steering shaft to move freely.
c. Remove starter motor.
d. Remove nuts on bottom of engine mounting insulator (LH), and lift up left side of engine approximately 3 cm (1.18 inch) with transmission jack.
e. Remove exhaust manifold cover (left bank).
f. Loosen nuts in the reverse order of figure to remove exhaust manifold and three way catalyst (left bank) with power tool.
A: Left bank
B: Right bank
<-: Engine front
NOTE: Disregard No. 9 to No. 12 when loosening.
11. Remove exhaust manifold and three way catalyst (right bank) as follows:
a. Remove alternator and bracket.
b. Remove nuts on bottom of engine mounting insulator (RH), and lift up right side of engine approximately 3 cm (1.18 inch) with transmission jack.
c. Remove exhaust manifold cover (right bank).
d. Loosen nuts in the reverse order of figure to remove exhaust manifold and three way catalyst (right bank) with power tool.
A: Left bank
B: Right bank
<-: Engine front
NOTE: Disregard No. 9 to No. 12 when loosening.
12. Remove exhaust manifold gaskets.
CAUTION: Cover engine openings to avoid entry of foreign materials.
INSPECTION AFTER REMOVAL
Surface Distortion
^ Check the surface distortion of the each exhaust manifold flange mating surface with straightedge and feeler gauge.
Limit: 0.3 mm (0.012 inch)
^ If it exceeds the limit, replace exhaust manifold and three way catalyst.
INSTALLATION
Note the following, and install in the reverse order of removal.
Exhaust Manifold Gasket
Install exhaust manifold gasket with its directional protrusion set upward.
A: Protrusion for confirming installation
<-: Above
Exhaust Manifold
^ Install exhaust manifold and tighten mounting nuts in numerical order as shown in the figure.
A: Left bank
B: Right bank
<-: Engine front
NOTE: Tighten mounting nuts No. 1 to 4 in two steps. The numerical order No. 9 to 12 shown second steps.
Air Fuel Ratio Sensor
CAUTION:
^ Before installing a new air fuel ratio sensor 1, clean exhaust system threads using oxygen sensor thread cleaner (commercial service tool: J-43897-18 or J-43897-12), and apply anti-seize lubricant (commercial service tool).
^ Do not over torque air fuel ratio sensor. Doing so may cause damage to the air fuel ratio sensor 1, resulting in MIL coming on.