Exhaust Manifold: Service and Repair

EXHAUST MANIFOLD AND THREE WAY CATALYST

Removal and Installation












REMOVAL LH (M/T MODELS)


WARNING:
Perform the work when the exhaust and cooling system have completely cooled down.
NOTE:
When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spilling.
1.Partially drain engine coolant. Service and Repair.
2.Drain power steering fluid. Draining.
3.Remove battery tray. Removal And Installation Coupe (Coupe models) or Removal And Installation Sedan (Sedan models).
4.Remove engine room cover.
5.Remove front air duct, air duct hose and air cleaner case assembly. Service and Repair.
6.Remove engine cooling fan. Removal and Installation.
7.Disconnect heater hose from the engine.
8.Remove front suspension member. Removal And Installation.
9.Remove the front engine mounting bracket from the engine. Removal and Replacement.
10.Remove the LH three way catalyst supports.
11.Remove heated oxygen sensor 2 and air fuel ratio (A/F) sensor 1.
a.Remove harness connector of each sensor, and disconnect the harness from the bracket and middle clamp.
b.Remove both heated oxygen sensor and air fuel ratio (A/F) sensor using Tool.






CAUTION:
- Be careful not to damage heated oxygen sensor or air fuel ratio (A/F) sensor.
- Discard any heated oxygen sensor 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.
12.Remove exhaust manifold and three way catalyst heat shield with power tool.
13.Remove the three way catalyst (manifold) by loosening the bolts first and then removing the nuts and through bolts.





14.Remove the exhaust manifold (B). Loosen the exhaust manifold nuts in the order as shown.






REMOVAL RH (M/T MODELS)


WARNING:
Perform the work when the exhaust and cooling system have completely cooled down.
1.Drain power steering fluid. Draining.
2.Remove engine room cover.
3.Remove front air duct, air duct hose and air cleaner case assembly. Service and Repair.
4.Remove cowl top. Coupe (Coupe models) or Sedan (Sedan models).
5.Disconnect EVAP hose and brake booster vacuum hose.
6.Remove front suspension member. Removal And Installation.
7.Remove the rear engine mounting bracket from the engine. Removal and Replacement.
8.Remove the RH three way catalyst supports.
9.Remove heated oxygen sensor 2 and air fuel ratio (A/F) sensor 1.
a.Remove harness connector of each sensor, and disconnect the harness from the bracket and middle clamp.
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b.Remove both heated oxygen sensor and air fuel ratio (A/F) sensor using Tool.






CAUTION:
- Be careful not to damage heated oxygen sensor or air fuel ratio (A/F) sensor.
- Discard any heated oxygen sensor 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.
10.Remove exhaust manifold and three way catalyst heat shield with power tool.
11.Remove the three way catalyst (manifold) by loosening the bolts first and then removing the nuts and through bolts.





12.Remove the exhaust manifold (A). Loosen the exhaust manifold nuts in the order as shown.






REMOVAL (CVT MODELS)


WARNING:
- Perform the work when the exhaust and cooling system have completely cooled down.
- When removing the front and rear engine mounting through bolts and nuts, lift the engine up slightly for safety. For engine slingers, Removal and Replacement.
1.Remove the engine and transaxle assembly. Removal and Replacement.
2.Remove the RH and LH three way catalyst supports.
3.Remove heated oxygen sensor 2 (bank 1), heated oxygen sensor 2 (bank 2), air fuel ratio (A/F) sensor 1
(bank 1) and air fuel ratio (A/F) sensor 1 (bank 2).
a.Remove harness connector of each sensor, and disconnect the harness from the bracket and middle clamp.
b.Remove both heated oxygen sensors and air fuel ratio (A/F) sensors using Tool.






CAUTION:
- Be careful not to damage heated oxygen sensors or air fuel ratio (A/F) sensors.
- Discard any heated oxygen sensor 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.
4.Remove exhaust manifold and three way catalyst heat shields with power tool.
5.Remove the three way catalyst (manifold) (bank 1) and three way catalyst (manifold) (bank 2) by loosening the bolts first and then removing the nuts and through bolts.





6.Remove the exhaust manifolds RH (A) and LH (B). Loosen the exhaust manifold nuts in the order as shown.











INSPECTION AFTER REMOVAL

Surface Distortion





- Use a reliable straightedge and feeler gauge to check the flatness of the exhaust manifold mating surfaces.
Limit: 0.3mm (0.012 in)

INSTALLATION

Installation is in the reverse order of removal.





- Install the exhaust manifold nuts in the order as shown RH (A) and
LH (B).










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CAUTION:
- Before installing a heated oxygen sensor or air fuel ratio (A/F) sensor, clean the exhaust manifold threads using the oxygen sensor thread cleaner tool, and apply anti-seize lubricant.
Tool numbers: J-43897-18
: J-43897-12
- Do not over-tighten the air fuel ratio (A/F) sensor or heated oxygen sensors. Doing so may cause damage.
Tool numbers: KV10114400 (J-38365)
: KV991J0050 (J-44626)