Exhaust Manifold and Three Way Catalyst

EXHAUST MANIFOLD AND THREE WAY CATALYST

EXHAUST MANIFOLD AND THREE WAY CATALYST:

REMOVAL
1. Remove heated oxygen sensors.
Follow below steps to remove each heated oxygen sensor.

a. Remove engine under cover and 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, remove both left and right heated oxygen sensors.

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 mm (19.7 inch) onto a hard surface such as a concrete floor; use a new one.

2. Remove exhaust manifold and three way catalyst (left bank) in below steps.
a. Remove A/C compressor with power tool and put it a side with piping connected.
b. Remove exhaust front tube with power tool.
c. Remove nuts on bottom of left engine mounting insulator, and lift up left side of engine approximately 3 cm (1.18 inch) with bans mission jack.
d. Support and lift up bottom of engine with bans mission jack. Remove left engine mount insulator along with left engine mount brackets.







e. Remove exhaust manifold cover.
f. Loosen nuts in reverse order of illustration to remove exhaust manifold and three way catalyst.

CAUTION: Disregard the numerical order No. 9 to 12 in removal.

3. Remove exhaust manifold and three way catalyst (right bank) loosening nuts in reverse order in the figure.
a. Remove battery and tray.
b. Remove radiator reservoir tank and bracket.
c. Remove exhaust front tube with power tool.
d. Support and lift up bottom of engine with transmission jack. Remove right engine mount insulator along with right engine mount brackets.
e. Remove starter motor with power tool.
f. Remove exhaust manifold cover.
g. Loosen nuts in reverse order of illustration to remove exhaust manifold and three way catalyst with power tool.

CAUTION: Disregard the numerical order No. 9 to 12 in removal.


INSPECTION AFTER REMOVAL







Surface Distortion
Use a reliable straightedge and feeler gauge to check the flatness of exhaust manifold fitting surface.

Standard: 0.3 mm (0.012 inch)



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. Refer to illustration of components on former Dace

Exhaust Manifold Nuts:

Tightening Exhaust Manifold Nuts
Install exhaust manifold and three way catalyst in the numerical order shown in the figure.

Tighten nuts No. 1 to No. 4 in two steps. Order No. 9 to 12 shows second step.


Installation of Heated Oxygen Sensor

CAUTION: When using heated oxygen sensor wrench (KV10114400), 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 oxygen sensor thread clearer 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.