Removal and Installation

EXHAUST MANIFOLD AND THREE WAY CATALYST


Removal and Installation


REMOVAL

WARNING:
Perform the work when the exhaust and cooling system have cooled sufficiently.
1. Remove the air duct and resonator assembly. Refer to Removal and Installation.
2. Drain the engine coolant from the radiator. Refer to Changing Engine Coolant.
3. Remove the engine undercover using power tool.
4. Remove the radiator and radiator hoses. Refer to Removal and Installation.
5. Remove the drive belts. Refer to Testing and Inspection.
6. Remove the air fuel ratio A/F sensors (bank 1, bank 2).
- Follow steps below to remove each air fuel ratio A/F sensor.
a. Remove the harness connector of each air fuel ratio A/F sensor, and harness from bracket and middle clamp.





b. Remove the air fuel ratio A/F sensors from both LH and RH exhaust manifolds using Tool.

Tool number : - (J-44626)

CAUTION:
- Do not damage the air fuel ratio A/F sensors
- Discard any air fuel ratio A/F sensor which has been dropped from a height of more than 0.5m (19.7 in) onto a hard surface such as a concrete floor. Replace it with a new one.
7. Remove the front cross bar.





8. Remove the exhaust manifold (LH) following the steps below.
- : Front a. Remove the exhaust front tube. Refer to Removal and Installation.
b. Remove the exhaust manifold cover.
c. Loosen the nuts in reverse order of illustration (A) using power tool.
d. Remove the exhaust studs from positions 2, 4, 6, 8 and remove exhaust manifold (LH).
9. Remove the exhaust manifold (RH) following the steps below.
a. Remove the exhaust front tube. Refer to Removal and Installation.
b. Remove the oil level gauge guide. Refer to Disassembly and Assembly.
c. Remove the exhaust manifold cover.
d. Loosen the nuts in reverse order of illustration (B) using power tool.
e. Remove the exhaust studs from positions 2, 4, 6, 8 and remove exhaust manifold (RH).

INSPECTION AFTER REMOVAL

Surface Distortion
- Check the flatness of each exhaust manifold flange surface using suitable tools.





Flatness limit : 0.3 mm (0.012 in)

- If measurement exceeds the limit, replace the exhaust manifold.

INSTALLATION
Installation is in the reverse order of removal.





- Install new exhaust manifold gasket with the top of the triangular up mark on it facing up and its coated face (gray side) toward the exhaust manifold side.
- Tighten the exhaust manifold nuts in the numerical order shown.





Then recheck the torque of the nuts both (A) and (B).
- A: LH
- B: RH
- : Front
- Before installing new air fuel ration A/F sensors, clean the exhaust system threads using Tool and apply antiseize lubricant.

Tool number : - (J-43879-12)
: - (J-43897-18)

CAUTION:
- Do not over tighten the air fuel ratio A/F sensors. Doing so may cause damage to the sensor, resulting in the MIL coming on.