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.
1. Remove engine room cover (RH and LH). Component Removal and Installation.
2. Remove engine cover with power tool. Removal and Installation.
3. Remove air duct (inlet), air cleaner case and air duct and resonator assembly. Component Removal and Installation.
4. Remove front and rear engine undercovers with power tool.
5. Drain engine coolant from radiator. Changing Engine Coolant.

CAUTION:
- Perform this step when engine is cold.
- Never spill engine coolant on drive belts.
6. Remove radiator. Component Removal and Installation.
7. Remove drive belts. Component Procedures Adjustments Removal and Installation.
8. Remove exhaust front tube with power tool. Testing and Inspection Component.
9. Remove each air fuel ratio sensor 1 as follows:
a. Disconnect harness connector of each air fuel ratio sensor 1.





b. Remove each 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 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. Service and Repair.
b. Remove steering lower joint to enable steering shaft to move freely. Service and Repair.
c. Remove starter motor. Removal and Installation.
d. Remove nuts on bottom of engine mounting insulator (LH), and lift up left side of engine approximately 3 cm (1.18 in) with transmission jack. (2WD models) or Component (AWD models).
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
White arrow: 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. Description and Operation.
b. Remove nuts on bottom of engine mounting insulator (RH), and lift up right side of engine approximately 3 cm (1.18 in) with transmission jack. (2WD models) or Component (AWD models).
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
White arrow: 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 in)

- 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
White arrow: Above

Exhaust Manifold





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

A: Left bank
B: Right bank
White arrow: 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 1

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).
- Never over torque air fuel ratio sensor 1. Doing so may cause damage to the air fuel ratio sensor 1, resulting in "MIL" coming on.