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Removal and Installation
 
 
REMOVAL
 
 
2WD models
1. Remove the engine cover.(With engine cover models) Refer to Removal and Installation.Removal and Installation
2. Disconnect the air fuel ratio sensor 1 harness connector.
3. Remove the air fuel ratio sensor 1 using heated oxygen sensor wrench [SST: KV10117100] if necessary.
4. Remove the engine under cover. Refer to Removal and Installation.
5. Remove the exhaust front tube. Refer to Removal and Installation.
6. Remove the exhaust manifold and three way catalyst bracket.
7. Remove the EGR inlet tube heat insulator. Refer to Removal and Installation.
8. Remove the EGR inlet tube mounting bolt, exhaust manifold and three way catalyst side. Refer to Removal and Installation.
9. Remove the exhaust manifold and three way catalyst cover.
10. Loosen the exhaust manifold and three way catalyst nuts in the reverse order as shown.
11. Remove the exhaust manifold and three way catalyst assembly and gasket.
 
 
AWD models
 
 
1. Remove the engine cover (with engine cover models). Refer to Removal and Installation.Removal and Installation
2. Disconnect the exhaust gas temperature harness connector.
3. Remove the exhaust gas temperature sensor.
4. Disconnect the air fuel ratio sensor 1 harness connector.
5. Remove the air fuel ratio sensor 1 using heated oxygen sensor wrench [SST: KV10117100] if necessary.
6. Remove the engine under cover. Refer to Removal and Installation.
7. Remove the exhaust front tube. Refer to Removal and Installation.
8. Remove rear propeller shaft. Refer to Removal and Installation.
9. Remove the exhaust manifold and three way catalyst bracket.
10. Remove the EGR inlet tube heat insulator. Refer to Removal and Installation.
11. Remove the EGR inlet tube mounting bolt, exhaust manifold and three way catalyst side. Refer to Removal and Installation.
12. Remove the exhaust manifold and three way catalyst cover.
13. Loosen the exhaust manifold and three way catalyst nuts in the reverse order as shown.
14. Remove the exhaust manifold and three way catalyst assembly and gasket.
 
 
INSTALLATION
 
 
Exhaust Manifold and Three Way Catalyst
1. Install studs in cylinder head and exhaust manifold and three way catalyst if removed. Then tighten to specification.
cautionDo not reuse stud bolts.
2. Install the exhaust manifold and three way catalyst and gasket. Then tighten the nuts to specification in the numerical order shown.
: 41.65 N·m (4.2 kg-m, 31 ft-lb)
caution
  • Do not reuse gasket.
  • Do not reuse nuts.
3. Then tighten the nuts to specification in the numerical order shown again.
: 41.65 N·m (4.2 kg-m, 31 ft-lb)
4. Install exhaust manifold and three way catalyst cover and bolts.
cautionDo not reuse bolts.
5. Install the air fuel ratio sensor 1 using heated oxygen sensor wrench [SST: KV10117100] if removed and tighten to specification.
caution
  • Be careful not to damage air fuel ratio sensor 1.
  • Discard any air fuel ratio 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 one.
  • Do not over-tighten the air fuel ratio sensor 1. Doing so may cause damage to the air fuel ratio sensor 1, resulting in a malfunction and the MIL coming on.
6. Install the exhaust gas temperature sensor to the specified torque.
caution
  • Be careful not to damage exhaust gas temperature sensor.
  • Discard any exhaust gas temperature 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 one.
  • Do not over-tighten the exhaust gas temperature sensor. Doing so may cause damage to the exhaust gas temperature sensor, resulting in a malfunction and the MIL coming on.