Catalytic Converter: Service and Repair

Three-way Catalytic Converter (TWC) System (Part 1):

Three-way Catalytic Converter (TWC) System (Part 2):

THREE-WAY CATALYTIC CONVERTER (TWC) SYSTEM

REPLACEMENT

1. REMOVE ENGINE COVER

2. REMOVE AIR CLEANER INLET

3. REMOVE AIR CLEANER, MAF METER AND INTAKE AIR RESONATOR ASSEMBLY

4. DISCONNECT HEATED OXYGEN SENSORS FROM EXHAUST MANIFOLD
a. Disconnect the 3 oxygen sensor connectors.
b. Disconnect the 2 oxygen sensors (bank 1 sensor 1, 2) from the exhaust manifold.

5. REMOVE FRONT EXHAUST PIPE (WITH REAR TWC)
a. Take out the front side of the floor carpet.
b. Disconnect the oxygen sensor connector.
c. Remove the 2 bolts and pipe support bracket.
d. Remove the 5 bolts, front exhaust pipe and 3 gaskets.




6. REMOVE EXHAUST MANIFOLD (WITH FRONT TWC)
a. Using a 14 mm deep socket wrench, remove the 8 nuts, the exhaust manifold and 2 gaskets.
b. Remove the heated oxygen sensor (bank 2 sensor 1) form the exhaust manifold.

7. REINSTALL EXHAUST MANIFOLD (WITH FRONT TWC)
a. Install the heated oxygen sensor (bank 2 sensor 1) to the exhaust manifold.
Torque: 45 N.m (450 kgf.cm, 33 ft.lbf)

b. Install 2 new gaskets to the cylinder head.
c. Using a 14 mm deep socket wrench, install new exhaust manifold with 8 new nuts. Uniformly tighten the nuts in several passes.

Torque: 40 N.m (408 kgf.cm, 30 ft.lbf)

8. REINSTALL FRONT EXHAUST PIPE (WITH REAR TWC)
a. Reinstall new 3 gaskets, and front exhaust pipe with 5 bolts and support bracket.
b. Reinstall the pipe support bracket with 2 bolts.

9. RECONNECT HEATED OXYGEN SENSORS TO EXHAUST MANIFOLD
a. Install the 2 oxygen sensors (bank 1 sensor 1, 2) to the exhaust manifold.
Torque: 45 N.m (450 kgf.cm, 33 ft.lbf)

b. Connect the 3 oxygen sensor connectors.

10. REINSTALL AIR CLEANER, MAF MATER AND INTAKE AIR RESONATOR ASSEMBLY

11. REINSTALL AIR CLEANER INLET

12. REINSTALL ENGINE COVER