Removal and Installation

EXHAUST MANIFOLD AND THREE WAY CATALYST


Removal and Installation


REMOVAL

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

NOTE:
When removing bank 1 side parts only, step 3, 10 and 11 are unnecessary.
1. Remove engine room cover (RH and LH). Refer to Component.
2. Remove engine cover with power tool. Refer to Component Removal and Installation.
3. Drain engine coolant. Refer to Inspection.

CAUTION:
- Perform this step when engine is cold.
- Never spill engine coolant on drive belt.
4. Remove air cleaner case and air duct. Refer to Exploded View Removal and Installation.
5. Remove front and rear undercover with power tool.
6. Disconnect heated oxygen sensor harness connectors.

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.
7. Remove exhaust mounting bracket between three way catalysts (bank 1 and bank 2) and transmission. Refer to Component.
8. Remove exhaust front tube and three way catalysts (bank 1 and bank 2).





9. Disconnect harness connector and remove air fuel ratio sensor
1 on both banks using heated oxygen sensor wrench [SST:
KV10114400 (J38365)] (C).
- Put marks to identify installation positions of each air fuel ratio sensor 1.

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.
10. Disconnect steering lower joint at power steering gear assembly side, and release steering lower shaft. Refer to Removal and Replacement.
11. Remove water bypass pipe and heater pipe. Refer to Component.
12. Remove exhaust manifold cover.
13. Loosen mounting nuts in reverse order as shown in the figure to remove exhaust manifold.

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





14. Remove gaskets.

CAUTION:
Cover engine openings to avoid entry of foreign materials.

INSPECTION AFTER REMOVAL

Surface Distortion
- Check the surface distortion of the exhaust manifold mating surface with straightedge (A) and feeler gauge (B).






Limit : 0.7 mm (0.028 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 exhaust manifold gasket in direction shown in the figure.





Exhaust Manifold
- If stud bolts were removed, install them and tighten to the specified torque below.

Torque: 14.7 N�m (1.5 kg-m, 11 ft-lb)

- Install mounting exhaust manifold in numerical order as shown in the figure.

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






Air Fuel Ratio Sensor 1 and Heated Oxygen Sensor 2

CAUTION:
- Before installing a new air fuel ratio sensor 1 and heated oxygen sensor 2, clean exhaust system threads using oxygen sensor thread cleaner (commercial service tool: J-43897-18 or J43897-12) and apply anti-seize lubricant (commercial service tool).
- Never over torque air fuel ratio sensor 1 and heated oxygen sensor 2. Doing so may cause damage to air fuel ratio sensor 1 and heated oxygen sensor 2, resulting in the "MIL" coming on.