Procedure C

Procedure C: Remove the Exhaust Manifold/Catalyst as follows:

Remove Alternator:

IMPORTANT:
Make sure the negative battery cable is disconnected.





1. This Step For Altima ONLY: Re-position (lift up about an inch) the Relay Box to allow enough clearance for removing the Lower Alternator Mounting Bolt. See Figure C1.

^ Remove one nut at the lower front of the Relay Box (see Figure C1).

^ Use a flat-blade screwdriver to release the Clip on the side (facing the Alternator) of the Relay Box (see Figure C1).

^ Now go to step 3, below.

2. This Step For Sentra ONLY:

^ Remove both upper radiator mounting brackets.

^ Remove the passenger-side front inner fender well in order to remove the alternator.

^ Now go to step 3, below.

3. Remove the top Plastic Engine Cover (as applicable).





4. Remove all electrical connectors from the Alternator (see Figure C2).

5. Remove the Alternator Drive Belt (see Figure C2).

6. Remove the Alternator Mounting Bolts (see Figure C2).





IMPORTANT:
Prevent the belt tensioner from loosing its tension by inserting a screwdriver (or other suitable device) through the tensioner mounting hole (see Figure C3).

7. Remove the Alternator from the vehicle.

Remove Oxygen Sensor Wire Harness:





8. Disconnect the Oxygen Sensor Connector (see Figure C4).

9. Remove the Oxygen Sensor Wire Harness from the Upper Front Exhaust Manifold/Catalyst Heat Shield Clips.

Remove Upper Front Exhaust Manifold/Catalyst Heat Shield:

10. Remove Upper Front Exhaust Manifold/Catalyst Heat Shield:





^ Carefully remove four screws that secure the Heat Shield (see Figure C5).

IMPORTANT:
Use Genuine Nissan Rust Penetrant 999MP-A3020P (or equivalent). Loosen screws 1/2 turn with hand-tool (do not use power tool) and apply rust penetrant before removing screws completely.

^ Remove the Heat Shield

Disconnect Front Exhaust Pipe From Exhaust Manifold/Catalyst:





11. Remove the two nuts that secure the Front Exhaust Pipe to the Exhaust Manifold/Catalyst (see Figure C6). Discard the old gasket. You'll be installing a new one later.

NOTE:
The stud(s) may come out of the Catalyst when removing the nut - this is okay. Just re-install them later.

^ Remove Exhaust Manifold/Catalyst Support Bracket Bolts:





12. Loosen the bolt that secures the bracket to the engine block, and remove the bolt that secures the bracket to the Exhaust Manifold/Catalyst (see Figure C7).

^ Remove Exhaust Manifold/Catalyst:





13. Remove five nuts that secure the Exhaust Manifold/Catalyst to the cylinder head (see Figure C8).

IMPORTANT:
Use Genuine Nissan Rust Penetrant 999MP-A3020P (or equivalent). Loosen screws 1/2 turn with hand-tool (do not use power tool) and apply rust penetrant before removing screws completely.

14. Remove the Exhaust Manifold/Catalyst from the vehicle.

15. Inspect the inlet and outlet of the Exhaust Manifold/Catalyst for any Power Valve Screws/Plates.

^ Shake the Exhaust Manifold/Catalyst upside down to see if any Screws/Plates fall out of the Catalyst.

16. Refer back to the Repair Flow Chart (Shown at the beginning of this bulletin) for the next applicable step.