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 air duct (inlet), air cleaner case and mass air flow sensor assembly, air duct and resonator assembly.
2. Drain engine coolant from the radiator.
3. Remove engine front and rear undercovers with power tool.
4. Disconnect radiator upper hose.
5. Remove the lower radiator shroud.
6. Remove the radiator shroud.
7. Disconnect A/T fluid cooler hoses.
^ Install blind plug to avoid leakage of A/T fluid.

8. Remove radiator.
9. Remove drive belts.
10. Remove heated oxygen sensors.
^ Follow below steps to remove each heated oxygen sensor.

a. Remove engine cover with power tool.





b. Remove harness connector of each heated oxygen sensor. and harness from bracket and middle clamp.
c. Using heated oxygen sensor wrench (SST), remove both left and right heated oxygen sensor 1 and 2 on both LH and RH bank.

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 m (19.7 inch) onto a hard surface such as a concrete floor; replace with a new one.

11. Remove front cross bar.
12. Remove exhaust manifold (LH bank) in below steps.
a. Disconnect A/C piping from A/C compressor, then remove A/C compressor with power tool.
b. Remove exhaust front tube with power tool.
c. Remove steering lower joint to enable steering shaft to move freely.
d. Remove three way catalyst.
e. Remove exhaust manifold cover.





f. Loosen nuts in reverse order of illustration to remove exhaust manifold with power tool.

NOTE: Exclude No. 9 to No. 12 in removal.

13. Remove exhaust manifold (RH bank) in below steps.
a. Remove alternator harness bracket.
b. Remove alternator and bracket.
c. Remove exhaust front tube with power tool.
d. Remove three way catalyst.
e. Remove exhaust manifold cover.
f. Loosen nuts in reverse order of illustration to remove exhaust manifold with power tool.

NOTE: Exclude No. 9 to No. 12 in removal.

INSPECTION AFTER REMOVAL
Surface Distortion





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

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

Exhaust Manifold Gasket
^ Install exhaust manifold gasket with its directional protrusion set upward.

Tightening Exhaust Manifold Nuts





^ Install exhaust manifold in the numerical order shown in the figure.
^ Tighten nuts No. 1 to No. 4 in two steps. The numerical order No. 9 to No. 12 shown second steps.

Installation of Heated Oxygen Sensors

CAUTION:
^ Before installing a new heated oxygen sensor, clean exhaust system threads using oxygen sensor thread cleaner (commercial service tool: J-43897-18 or J-43897-12), and apply anti-seize 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.