Removal and Replacement

EXHAUST MANIFOLD AND THREE WAY CATALYST

Exploded View EM-25:

Removal and Installation
REMOVAL

WARNING: Perform the work when the exhaust and cooling system have completely cooled down.

1. Remove engine cover with power tool.
2. Remove air cleaner case and air duct.
3. Remove undercover with power tool.
4. Drain engine coolant.

CAUTION:
^ Perform this step when engine is cold.
^ Do not spill engine coolant on drive belts.





5. Disconnect harness connector and remove heated oxygen sensor 2 on both banks using heated oxygen sensor wrench (SST).

CAUTION:
^ Be careful not to damage heated oxygen sensor 2.
^ Discard any heated oxygen sensor 2 which has been dropped onto a hard surface such as a concrete floor. Replace with a new sensor.

6. Remove exhaust mounting bracket between three way catalyst (right and left bank) and transmission.
7. Remove three way catalyst.





8. Disconnect harness connector and remove air fuel ratio sensor 1 on both banks using 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 onto a hard surface such as a concrete floor. Replace with a new sensor.

9. Remove water pipe and heater pipe on both right and left side.
10. Remove exhaust manifold cover.





11. Loosen nuts in reverse order as shown in the figure to remove exhaust manifold with power tool.

NOTE: Disregard the numerical order No. 7 and No. 8 in removal.

12. Remove exhaust manifold gaskets.

INSPECTION AFTER REMOVAL
Surface Distortion





^ Check the surface distortion of the exhaust manifold mating surface with straightedge and feeler gauge.
Limit: 0.3 mm (0.012 in)
^ If it exceeds the limit, replace exhaust manifold.

INSTALLATION
Note the following, and install in the reverse order of removal.

Exhaust Manifold Gasket





^ Install in direction shown below. (Follow same procedure for both banks.)
^ Locate thick side of port connecting part on right side from technician's view.
^ Locate round press in thick side of port connecting part above center level line of port.

Exhaust Manifold
^ If stud bolts were removed, install them and tighten to the specified torque below.
Torque: 14.7 Nm (1.5 kg-m, 11 ft-lb)





^ Install exhaust manifold in numerical order as shown in the figure.

NOTE: Tighten nuts No. 1 and No. 2 in two steps. The numerical order No. 7 and No. 8 shows second step.

Air Fuel Ratio Sensor and Heated Oxygen Sensor

CAUTION:
^ Before installing a new air fuel ratio sensor or a new heated oxygen sensor, clean exhaust system threads using heated oxygen sensor thread cleaner tool (commercial service tool: J-43897-18 or J43897-12) and apply anti-seize lubricant (commercial service tool).
^ Do not over torque the air fuel ratio sensor and the heated oxygen sensor. Doing so may cause damage to the air fuel ratio sensor or the heated oxygen sensor, resulting in the "MIL" coming on.