Technical Repair Instructions

1. OPERATION FLOW CHART





2. LOCATION OF AFFECTED PARTS





3. AFFECTED VIN RANGE

4. PREPARATION





A. PARTS





B. TOOLS

5. VEHICLE DISASSEMBLY

1. REMOVE MANIFOLD COVER

2. REMOVE THE RADIATOR COWL COVER

3. REMOVE THE AIR INTAKE DUCT

4. REMOVE THE ENGINE UNDER COVERS





5. DISCONNECT THE HEATED 02 SENSORS

a. For Bank 1 Sensor 2.

1. Disconnect the heated Q2 sensor connector.

2. Remove the connector clamp.

3. Remove the two wire harness clamps.

NOTE:
Be careful not to damage the sensors while they are disconnected.





b. For Bank 2 Sensor 2

1. Disconnect the heated Q2 sensor connector.

2. Remove the connector clamp.

3. Remove the two wire harness clamps.

NOTE:
Be careful not to damage the sensors while they are disconnected.





6. REMOVE THE FRONT SECTION OF THE DRIVE SHAFT TO THE REAR DIFFERENTIAL (4WD ONLY)

a. Depress brake pedal and hold.

b. Place match marks on both flanges of the drive shaft.

c. Remove the 4 nuts bolts and washers.

d. Remove the front section of the drive shaft.

NOTE:
When removing the drive shaft, do not apply excessive force to universal joint. During and after the removal of the drive shaft, keep the universal joint at a straight angle (Do not flex more than 15 degrees.)





e. Insert the SST onto the output shaft to prevent oil leakage.

SST: 09325-20010 or equivalent

NOTE:
Do not damage the output shaft oil seal.

7. REMOVE THE NO. 3 FRONT EXHAUST PIPE SUB-ASSEMBLY





a. Remove the 2 bolts and compression springs.

b. Remove the 2 bolts and 2 nuts.

c. Remove the No. 3 front exhaust pipe subassembly and 3 gaskets.

8. REMOVE THE FRONT EXHAUST PIPE





a. Remove the 2 nuts.

b. Remove the 2 bolts on the clamp bracket.

c. Remove the front exhaust pipe.

9. REMOVE BANK 1 EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY





a. Remove the No. 1 exhaust manifold heat insulator.

b. Remove the manifold stay.

c. Disconnect the heated A/F sensor connector.

NOTE:
The connector release is on the engine harness side.

d. Using the sequence shown loosen and remove the 6 manifold nuts in several passes.

e. Remove the bank 1 exhaust manifold converter sub-assembly from the vehicle.

f. Remove the heated A/F sensor.

NOTE:
Apply penetrating oil around the hex portion of the A/F sensor to aid in removal.

g. Remove and discard the exhaust manifold to cylinder head gasket.

NOTE:
The exhaust gasket is extremely sharp.

h. Remove the heat shields around the converter.

10. REMOVE BANK 2 EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY





a. Remove the No. 3 manifold converter insulator.

b. Remove the No. 2 exhaust manifold heat insulator.

c. Disconnect the heated A/F sensor connector.

d. Using the sequence shown loosen and remove the 6 manifold nuts and one bolt in several passes.

e. Remove the bank 2 exhaust manifold converter sub-assembly from the vehicle.

f. Remove the heated A/F sensor.

NOTE:
Apply penetrating oil around the hex portion of the A/F sensor to aid in removal.

g. Remove and discard the exhaust manifold to cylinder head gasket.

11. INSPECTION OF OLD EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLIES

a. Shake each exhaust manifold converter assembly.

b. If either converter assembly rattles or clatters replace the engine oil and oil filter.

6. VEHICLE REASSEMBLY

1. INSTALL THE NEW BANK 2 EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

a. Reinstall the heated A/F sensor.

Torque:
44 Nm (449 kgf.cm, 32 ft.lbf)

b. Install the new exhaust manifold gasket onto the cylinder head. The shiny side faces the cylinder head.

c. Install the new bank 2 exhaust manifold converter sub-assembly.





d. Using the sequence shown tighten the 6 manifold nuts and one bolt in several passes.

Torque:
49 N.m (500 kgf.cm, 36 ft.lbf)

NOTE:
When tightening the six nuts and one bolt use multiple passes and in the sequence shown.

e. Retighten nuts number 1 and 2.

f. Reconnect the A/F sensor.

g. Reinstall the No. 2 exhaust manifold heat insulator

Torque:
8.5 Nm (87 kgf.cm, 75 in.lbf)

h. Reinstall the No. 3 manifold converter insulator.

Torque:
8.5 N.m (87 kgf.cm, 75 in.lbf)

2. INSTALL THE NEW BANK 1 EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

a. Reinstall the heated A/F sensor.

Torque:
44 N.m (449 kgf.cm, 32 ft.lbf)

b. Install the new exhaust manifold gasket onto the cylinder head.

c. Reinstall the heat shield around the converter.

d. Install the new bank 1 exhaust manifold converter sub-assembly.





e. Using the sequence shown tighten the 6 manifold nuts in several passes.

Torque:
49 N.m (500 kgf.cm, 36 ft.lbf)

NOTE:
When tightening the six nuts use multiple passes and in the sequence shown.

f. Retighten nuts number 1 and 2. Reconnect the A/F sensor.

g. Reinstall the manifold stay.

Torque:
34 N.m (347 kgf.cm, 25 ft.lbf)

h. Reinstall the no. 1 exhaust manifold heat insulator.

Torque:
8.5 Nm (87 kgf.cm, 75 in.lbf)

3. REINSTALL THE EXHAUST PIPES

NOTE:
Loosely install all the parts listed in Step 3, Reinstall the exhaust pipes. Then tighten all nuts and bolts to the specified torques.

a. Install the new studs into the exhaust manifold converter sub-assembly.

b. Install the new exhaust pipe gasket.

c. Reinstall the front exhaust pipe onto the vehicle.

d. Loosely install the 2 nuts.

Torque:
56 Nm (571 kgf.cm, 41 ft.lbf)

e. Reinstall the two clamp bolts.

Torque:
21 Nm (214 kgf.cm, 16 ft.lbf)





f. Reinstall the no. 3 exhaust pipe assembly.

1. Inspect the compression springs free length.

^ Using calipers measure the free length of the compression springs.

Minimum length:
41.5 mm (1.634 in.)

NOTE:
Replace any compression springs that are below minimum length.





g. Install a new gasket onto the No. 3 exhaust pipe as shown.

h. Install 2 new gaskets on to the No. 3 exhaust pipe.

i. Reinstall the 2 bolts.

Torque:
56 N.m (571 kgf.cm, 41 ft.lbf)

j. Install the 2 new nuts.

Torque:
56 Nm (571 kgf.cm, 41 ft.lbf)

k. Install the 2 bolts with the compression springs.

Torque:
48 N.m (490 kgf.cm, 35 ft.lbf)





4. REINSTALL THE FRONT SECTION OF THE DRIVE SHAFT (4WD only)

a. Remove SST from the output shaft.

b. Install the yoke on to the output shaft.

NOTE:
Do not damage the output shaft oil seal.

Do not damage the universal joint boot.





c. Align the match marks on the drive shaft flanges and reconnect the drive shaft with the 4 bolts nuts and washers.

Torque:
74 Nm (750 kgf.cm, 54 ft.lbf)





d. Confirm that each drive shaft universal joint is correctly positioned as shown in the illustration.

5. RECONNECT THE HEATED 02 SENSORS

6. CHECK FOR EXHAUST LEAKS





7. INSPECT OIL LEVEL IN TRANSFER CASE (4WD only)

a. Remove the No. 1 plug and gasket for the transfer case.

b. The transfer case oil level should be 0 to 5 mm below the bottom of the plug hole.

NOTE:
Ensure that the vehicle is level prior to checking transfer case oil level. An over or under filled transfer case may cause the 4WD system to operate improperly. When adding oil, pour it slowly and in several intervals. After adding oil allow time for the oil to settle before rechecking level.

c. Correct transfer case oil level as necessary.

d. Reinstall the No. 1 plug using a new gasket.

Torque:
49 Nm (500 kgf.cm, 36 ft.lbf)

8. CHANGE ENGINE OIL AND OIL FILTER, IF THE CONVERTERS HAVE FAILED INSPECTION

9. REINSTALL THE ENGINE UNDER COVERS

10. REINSTALL THE AIR INTAKE DUCT

11. REINSTALL THE RADIATOR COWL COVER

12. REINSTALL MANIFOLD COVER

7. SSC COMPLETION LABEL INSTALLATION





1. After completing the repair and before returning the vehicle to the owner, an SSC completion label that is enclosed in the owner's notification letter must be affixed to the left front door hinge post near the check strap.

2. The label is to be filled out as follows:

^ Write in SSC 3LE.

^ Write in the date the repair was performed.

^ Write in your dealer code.

3. Additional SSC completion labels, in sheets of 50 (P/N 00410-01917), may be ordered through the non-parts system.