Catalytic Converter: Service and Repair

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 cover with power tool.
2. Remove air cleaner case and air duct.
3. Remove front and rear engine undercover and front cross bar with power tool.
4. Disconnect heated oxygen sensors 2 (bank 1 and bank 2) harness connectors.





5. Using heated oxygen sensor wrench (SST), remove heated oxygen sensors 2 (bank 1 and bank 2).

CAUTION:
^ Be careful not to damage heated oxygen sensor.
^ Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 meters (19.7 inch) onto a hard surface such as a concrete floor; replace with a new sensor.

6. Remove bracket between right/left catalytic converter and transmission.
7. Remove three way catalyst (RH and LH bank).
8. Remove heated oxygen sensors 1 (bank 1 and bank 2) harness connectors and harness crip.





9. Using heated oxygen sensor wrench (SST), remove heated oxygen sensors 1 (bank 1 and bank 2).

CAUTION:
^ Be careful not to damage heated oxygen sensor.
^ Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 meters (19.7 inch) onto a hard surface such as a concrete floor; replace with a new sensor.

10. Remove water pipes on both RH and LH side.








11. Remove exhaust manifold cover (RH and LH bank).
12. Loosen nuts in the reverse order of illustration to remove exhaust manifold with power tool.

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

INSPECTION AFTER REMOVAL
Surface Distortion





^ Use a reliable straightedge and feeler gauge to check the flatness of exhaust manifold fitting surface.
Limit: 0.3 mm (0.012 inch)
^ If it exceeds the limit, replace the exhaust manifold.

INSTALLATION
Install in the reverse order of removal paying attention to the following

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 torque specified below.
14.7 Nm (1.5 kg-m, 11 ft. lbs.)
^ Install exhaust manifold in the numerical order as shown in the figure.
^ Tighten nuts No. 1 and No. 2 in two steps. The numerical order No. 7 and No. 8 shows second step.

Heated Oxygen Sensor

CAUTION:
^ When using heated oxygen sensor wrench [SST: KV10117200 (J38365)], tighten to the middle of specified torque because length of tool may induce slight indication increase. Do not tighten to the maximum specified torque.
^ Before installing a new heated oxygen sensor, clean exhaust system threads using heated oxygen sensor thread cleaner tool (Commercial Service Tool: J-43897-18 or J-43897-12) and apply antiseize lubricant.
^ Do not over torque the heated oxygen sensor. Doing so may cause damage to the heated oxygen sensor, resulting in the "MIL" coming on.