Exhaust Manifold: Service and Repair
EXHAUST MANIFOLD AND THREE WAY CATALYSTRemoval and Installation
Exploded View EM-22:
REMOVAL (LEFT BANK)
1. Remove air cleaner case and air duct.
2. Remove engine undercover with power tool.
3. Disconnect harness connector and remove heated oxygen sensor 2 on both banks using Tool.
Tool number: KV10114400 (J-38365)
CAUTION:
^ Be careful not to damage heated oxygen sensor 2.
^ Discard any heated oxygen sensor 2 which has been dropped from a height of more than 0.5 m (19.70 in) onto a hard surface such as a concrete floor; replace with a new sensor.
4. Remove center exhaust tube, main muffler and left front exhaust tube.
5. Remove exhaust manifold cover (left bank).
6. Disconnect harness connector and remove air fuel ratio sensor 1 (left bank) using Tool.
Tool number: KV991J0050 (J-44626)
CAUTION:
^ Be careful not to damage air fuel ratio sensor 1.
^ Discard any air fuel ratio sensor 1 which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; replace with a new sensor.
7. Remove three way catalyst (left bank).
8. Loosen nuts with power tool in reverse order as shown.
NOTE: Disregard the numerical order No. 7 and 8 in removal.
9. Remove gaskets.
CAUTION: Cover engine openings to avoid entry of foreign materials.
INSPECTION AFTER REMOVAL
Surface Distortion
^ Check the surface distortion of the exhaust manifold mating surface with straightedge and feeler gauge.
Limit: 0.3 mm (0.012 in)
^ If it exceeds the limit, replace exhaust manifold.
INSTALLATION (LEFT BANK)
Installation of the remaining components is in the reverse order of removal. Note the following:
Exhaust Manifold Gasket
Install in direction as shown.
Exhaust Manifold
^ If stud bolts were removed, install them and tighten to the specified torque.
Exhaust manifold stud torque: 14.7 Nm (1.5 kg-m, 11 ft-lb)
^ Install exhaust manifold and tighten nuts in numerical order as shown.
NOTE: Tighten nuts No. 1 and 2 in two steps. The numerical order No. 7 and 8 shown second step.
Heated Oxygen Sensor
CAUTION:
^ Before installing a new air fuel ratio sensor 1 and heated oxygen sensor 2, clean exhaust system threads using oxygen sensor thread cleaner and apply anti-seize lubricant.
Tool number
: ( - ) J-43897-12
: ( - ) J-43897 18
^ Do not over torque air fuel ratio sensor 1 and heated oxygen sensor 2. Doing so may cause damage to air fuel ratio sensor 1 and heated oxygen sensor 2, resulting in the "MIL" coming on.
REMOVAL (RIGHT BANK)
1. Remove engine assembly.
2. Loosen nuts with power tool in reverse order as shown.
NOTE: Disregard the numerical order No. 7 and 8 in removal.
3. Remove gaskets.
CAUTION: Cover engine openings to avoid entry of foreign materials.
INSPECTION AFTER REMOVAL
Surface Distortion
^ Check the surface distortion of the exhaust manifold mating surface with straightedge and feeler gauge.
Limit: 0.3 mm (0.012 in)
^ If it exceeds the limit, replace exhaust manifold.
INSTALLATION (RIGHT BANK)
Installation of the remaining components is in the reverse order of removal.
Note the following:
Exhaust Manifold Gasket
Install in direction as shown.
Exhaust Manifold
^ If stud bolts were removed, install them and tighten to the specified torque.
Exhaust manifold stud torque: 14.7 Nm (1.5 kg-m, 11 ft-lb)
^ Install exhaust manifold and tighten nuts in numerical order as shown.
NOTE: Tighten nuts No. 1 and 2 in two steps. The numerical order No. 7 and 8 shown second step.
Heated Oxygen Sensor
CAUTION:
^ Before installing a new air fuel ratio sensor 1 and heated oxygen sensor 2, clean exhaust system threads using oxygen sensor thread cleaner and apply anti-seize lubricant.
Tool number
: ( - ) J-43897-12
: ( - ) J-43897 18
^ Do not over torque air fuel ratio sensor 1 and heated oxygen sensor 2. Doing so may cause damage to air fuel ratio sensor 1 and heated oxygen sensor 2, resulting in the "MIL" coming on.