MONOLITHIC CONVERTER REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during exhaust manifold converter sub-assembly (TWC: Front Catalyst) removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced
Replaced Part or Performed Procedure Necessary Procedure Effect/Inoperative Function when Necessary Procedure not Performed Link

  • Replacement of air fuel ratio sensor

  • Gas leak from exhaust system is repaired

 Inspection After Repair

  • Poor idle, etc.

  • Engine start function, etc.

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CAUTION:


  • B008MHA

    When the engine is hot, do not touch high-temperature areas such as the engine or exhaust manifold converter sub-assembly.

  • Touching high-temperature areas such as the engine and exhaust manifold converter sub-assembly could result in burns.

  • B008KL2

    When the engine is hot, do not touch high-temperature areas such as the engine or exhaust pipe.

  • Touching high-temperature areas such as the engine and exhaust pipe could result in burns.

PROCEDURE


  1. REMOVE INTERCOOLER ASSEMBLY

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  2. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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  3. REMOVE NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL

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  4. REMOVE WATER GUARD PLATE LH

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  5. REMOVE COWL BODY MOUNTING REINFORCEMENT LH

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  6. REMOVE COWL BODY MOUNTING REINFORCEMENT RH

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  7. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY (for LHD)

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  8. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY (for RHD)

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  9. REMOVE DASH PANEL HEAT INSULATOR


  10. REMOVE RADIATOR COVER

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  11. REMOVE NO. 1 AIR CLEANER INLET

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  12. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE

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  13. REMOVE ENGINE WIRE


    1. B008LAXC02
      B008MD9 Bolt
      B008LL0 Nut
      B008MI7 Connector

      Disconnect the 7 connectors.

    2. Remove the bolt and nut.

    3. Disengage the 3 wire harness clamps.

    4. B008LHE

      Remove the 2 bolts and wire harness clamp bracket from the cylinder head sub-assembly.

  14. REMOVE VENTILATION HOSE


    1. B008LIIC02
      *1 Ventilation Hose
      *2 No. 4 Ventilation Hose

      Slide the 2 clips and remove the ventilation hose from the cylinder head cover sub-assembly and inlet No. 1 air duct sub-assembly.

    2. Slide the 2 clips and remove the No. 4 ventilation hose from the ventilation ejector and inlet No. 1 air duct sub-assembly.

  15. REMOVE VENTILATION EJECTOR


    1. B008M5Q

      Remove the bolt and separate the air tube assembly from the cylinder head cover sub-assembly.

    2. Remove the 2 bolts and ventilation ejector from the cylinder head cover sub-assembly.

    3. Remove the O-ring from the cylinder head cover sub-assembly.

  16. REMOVE AIR TUBE ASSEMBLY


    1. B008LW2C02
      *1 No. 2 Intercooler Water Hose
      *2 No. 3 Intercooler Water Hose

      Slide the 2 clips and disconnect the No. 2 intercooler water hose and No. 3 intercooler water hose from the turbocharger sub-assembly.

    2. B008LZ1C02
      *1 No. 2 Intercooler Water Hose
      *2 No. 3 Intercooler Water Hose

      Disconnect the No. 2 intercooler water hose and No. 3 intercooler water hose from the No. 1 water hose clamp bracket.

    3. B008M10

      Loosen the hose clamp and remove the air tube assembly from the turbocharger sub-assembly.

  17. REMOVE VACUUM REGULATING VALVE ASSEMBLY


    1. B008KCWC02
      *1 No. 2 Vacuum Transmitting Hose
      *2 No. 3 Vacuum Transmitting Hose
      *3 Vacuum Regulating Valve Assembly
      *4 No. 2 Vacuum Switching Valve Bracket

      Disconnect the No. 2 vacuum transmitting hose and No. 3 vacuum transmitting hose from the vacuum regulating valve assembly.

    2. Remove the 3 bolts and vacuum regulating valve assembly and No. 2 vacuum switching valve bracket from the cylinder head sub-assembly.

  18. REMOVE INLET NO. 1 AIR DUCT SUB-ASSEMBLY


    1. B008K96

      Disconnect the No. 1 vacuum transmitting hose assembly from the vacuum tank.

    2. B008M51

      Remove the 2 bolts and vacuum tank from the inlet No. 1 air duct sub-assembly.

    3. B008LC9

      Disconnect the No. 1 vacuum transmitting hose assembly from the vacuum pump assembly.

    4. B008K8DC01

      Remove the bolt and disconnect the inlet No. 1 air duct sub-assembly from the fuel pump protector.

    5. B008KRL

      Disconnect the intake air control valve (air by-pass valve assembly) connector.

    6. B008MEHC02
      *1 No. 2 Vacuum Transmitting Hose Assembly
      *2 Inlet No. 1 Air Duct Sub-assembly

      Disconnect the No. 2 vacuum transmitting hose assembly from the turbocharger sub-assembly.

    7. Loosen the hose clamp and remove the inlet No. 1 air duct sub-assembly from the turbocharger sub-assembly.

  19. REMOVE AIR FUEL RATIO SENSOR

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  20. REMOVE NO. 1 ENGINE COVER


    1. B008LWG

      Remove the No. 1 engine cover from the cylinder head cover sub-assembly and cylinder head sub-assembly.

  21. REMOVE FRONT FLOOR COVER LH (w/ Cover)


  22. REMOVE FRONT FLOOR COVER RH (w/ Cover)

    Tech Tips

    Perform the same procedure as for the front floor cover LH.

  23. REMOVE FRONT FLOOR CENTER BRACE


  24. REMOVE FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst) (for 2WD)


    1. B008LV9

      Disconnect the heated oxygen sensor connector.

    2. Disengage the wire harness clamps.

    3. B008LC4

      Remove the 4 bolts and 4 compression springs and disconnect the front exhaust pipe assembly (TWC: Rear Catalyst) from the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and tail exhaust pipe assembly.

    4. Remove the front exhaust pipe assembly (TWC: Rear Catalyst) from the 2 exhaust pipe supports.

    5. Remove the 2 exhaust pipe gaskets from the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and tail exhaust pipe assembly.

  25. REMOVE NO. 2 CENTER EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst) (for AWD)


    1. B008LTF

      Remove the 4 bolts and disconnect the No. 2 center exhaust pipe assembly (TWC: Rear Catalyst) from the front exhaust pipe assembly and tail exhaust pipe assembly.

    2. Remove the No. 2 center exhaust pipe assembly (TWC: Rear Catalyst) from the 4 exhaust pipe supports.

  26. REMOVE FRONT EXHAUST PIPE ASSEMBLY (for AWD)


    1. B008KGY

      Disconnect the heated oxygen sensor connector.

    2. Disengage the wire harness clamp.

    3. B008M5W

      Remove the 2 nuts and disconnect the front exhaust pipe assembly from the exhaust manifold converter sub-assembly (TWC: Front Catalyst).

    4. Remove the exhaust pipe gasket from the front exhaust pipe assembly.

  27. REMOVE FRONT NO. 1 FLOOR HEAT INSULATOR


    1. B008LOI

      Remove the 3 nuts and front No. 1 floor heat insulator from the vehicle body.

  28. REMOVE DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY (for 2WD)


    1. B008LHW

      Remove the bolt, nut and drive shaft heat insulator sub-assembly from the cylinder block sub-assembly and manifold support bracket.

  29. REMOVE MANIFOLD SUPPORT BRACKET (for 2WD)


    1. B008LWZ

      Remove the 3 bolts and manifold support bracket from the cylinder block sub-assembly and exhaust manifold converter sub-assembly (TWC: Front Catalyst).

  30. REMOVE MANIFOLD SUPPORT BRACKET (for AWD)


    1. B008KK8

      Remove the 3 bolts and manifold support bracket from the cylinder block sub-assembly and exhaust manifold converter sub-assembly (TWC: Front Catalyst).

  31. REMOVE PROPELLER SHAFT HEAT INSULATOR (for AWD)


    1. B008KN6

      Remove the 3 bolts and propeller shaft heat insulator from the transfer assembly.

  32. REMOVE PROPELLER SHAFT HEAT INSULATOR BRACKET SUB-ASSEMBLY (for AWD)


    1. B008LX0

      Remove the 2 bolts and propeller shaft heat insulator bracket sub-assembly from the transfer assembly.

  33. REMOVE NO. 1 MANIFOLD CONVERTER INSULATOR (for AWD)


    1. B008KDO

      Remove the 4 bolts and No. 1 manifold converter insulator from the exhaust manifold converter sub-assembly (TWC: Front Catalyst).

  34. REMOVE NO. 2 MANIFOLD CONVERTER INSULATOR (for AWD)


    1. B008KGK

      Remove the 3 bolts and No. 2 manifold converter insulator from the exhaust manifold converter sub-assembly (TWC: Front Catalyst).

  35. REMOVE NO. 2 TURBO INSULATOR


    1. B008MH0

      Remove the 2 bolts and No. 2 turbo insulator from the cylinder head sub-assembly and heat insulator bracket.

  36. REMOVE NO. 1 MANIFOLD CONVERTER INSULATOR (for 2WD)


    1. B008KTX

      Remove the 3 bolts and No. 1 manifold converter insulator from the exhaust manifold converter sub-assembly (TWC: Front Catalyst).

  37. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (TWC: Front Catalyst)


    1. B008M3LC01
      *A for 2WD
      *B for AWD

      Remove the 4 nuts and exhaust manifold converter sub-assembly (TWC: Front Catalyst) from the turbocharger sub-assembly.

  38. REMOVE OUTLET TURBINE ELBOW GASKET


    1. B008KVE

      Remove the outlet turbine elbow gasket from the turbocharger sub-assembly.