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EM-30
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EXHAUST MANIFOLD AND THREE WAY CATALYST
EXHAUST MANIFOLD AND THREE WAY CATALYST
Exploded ViewINFOID:0000000006055156
Removal and InstallationINFOID:0000000006055157
REMOVAL
WARNING:
Perform the work when the exhaust and cooling system have cooled sufficiently.
1. Remove the engine undercover (rear) using power tool (4WD models).
2. Remove front final drive assembly (4WD models). Refer to DLN-212, "
Removal and Installation".
3. Remove the main muffler assembly and center exhaust tube. Refer to EX-6, "
Removal and Installation".
4. Remove the front exhaust tubes. Refer to EX-6, "
Removal and Installation".
5. Remove front tires. Refer to WT-48, "
Rotation".
6. Remove fender protectors. Refer to EXT-23, "
Removal and Installation".
7. Remove the LH and RH air fuel ratio A/F sensors. • Follow steps below to remove each air fuel ratio A/F sensor.
a. Remove the harness connector of each air fuel ra tio A/F sensor, and harness from bracket and middle
clamp.
1. Air fuel ratio A/F sensor 1 (bank 2) 2. Exhaust manifold cover (bank 2) 3. Exhaust manifold (bank 2)
4. Gaskets 5. Exhaust manifold (bank 1) 6. Exhaust manifold cover (bank 1)
7. Air fuel ratio A/F sensor 1 (bank 1) A. Up B. Coated face
C. Manifold side D. Up mark Front
AWBIA0453GB
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EXHAUST MANIFOLD AND THREE WAY CATALYST
EM-31
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b. Remove the air fuel ratio A/F sensors from both LH and RH
exhaust manifolds using Tool.
CAUTION:
• Do not damage the air fuel ratio A/F sensors
• Discard any air fuel rati o A/F sensor which has been
dropped from a height of more than 0.5m (19.7 in) onto a
hard surface such as a concrete floor. Replace it with a
new one.
8. Support the engine using a suitable tool.
9. Remove the exhaust manifold (LH) (A) following the steps below.
• : Front
• B: Exhaust manifold (RH)
a. Remove the engine mounting insulator. Refer to EM-78,
"Removal and Installation".
b. Remove the exhaust manifold cover.
c. Remove the engine mounting bracket. Refer to EM-78,
"Removal and Installation".
d. Loosen the nuts in reverse order as shown using power tool.
e. Remove the exhaust manifold (LH) (A).
10. Remove the exhaust manifold (RH) (B) following the steps below.
• : Front
• A: Exhaust manifold (LH)
a. Remove the engine mounting insulator. Refer to EM-78,
"Removal and Installation".
b. Remove the exhaust manifold cover.
c. Remove the engine mounting bracket. Refer to EM-78,
"Removal and Installation".
d. Remove the oil level gauge guide. Refer to EM-33, "
Removal
and Installation".
e. Loosen the nuts in reverse order as shown using power tool.
f. Remove the exhaust manifold (RH) (B).
INSPECTION AFTER REMOVAL
Surface Distortion
• Check the flatness of each exhaust manifold flange surface using suitable tools.
• If measurement exceeds the limit, replace the exhaust manifold.
INSTALLATION
Installation is in the reverse order of removal. Tool number
: — (J-44626)
WBIA0630E
AWBIA0814ZZ
AWBIA0814ZZ
Flatness limit : 0.3 mm (0.012 in)
KBIA2504E
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EM-32
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EXHAUST MANIFOLD AND THREE WAY CATALYST
• Install new exhaust manifold gasket with the top of the triangularup mark on it facing up and its coated face (gray side) toward the
exhaust manifold side.
• Tighten the exhaust manifold nuts LH and RH in the numerical order shown. Then recheck the torque of the nuts.
- A: Exhaust manifold (LH)
- B: Exhaust manifold (RH)
- : Front
• Before installing new air fuel ratio A/F sensors, clean the exhaust system threads using suitable tool and
apply anti-seize lubricant.
CAUTION:
• Do not over tighten the air fuel ratio A/F se nsors. Doing so may cause damage to the sensor,
resulting in the MIL coming on.
KBIA2553E
AWBIA0814ZZ
Oxygen sensor thread cleaner : (J-43897-12)
Oxygen sensor thread cleaner : (J-43897-18)
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OIL PAN AND OIL STRAINEREM-33
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OIL PAN AND OIL STRAINER
Removal and InstallationINFOID:0000000001538816
REMOVAL
WARNING:
To avoid the danger of being scalded, never drain the engine oil when the engine is hot.
1. Remove the engine. Refer to
EM-78, "
Removal and Installation".
2. Remove the oil pan (lower) using the following steps.
a. Remove the oil pan (lower) bolts using power tool.
1. Oil pan (upper) 2. O-ring3. O-ring
4. O-ring 5. O-ring (with collar)6. Oil level gauge guide
7. Oil level gauge 8. O-ring9. Connector bolt
10. Oil filter 11. Oil cooler12. Relief valve
13. Oil pressure switch 14. Gasket15. Drain plug
16. Oil pan (lower) 17. Oil strainer
KBIA2465E
KBIA2466E
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EM-34
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OIL PAN AND OIL STRAINER
b. Insert Tool between the lower oil pan and the upper oil pan.CAUTION:
• Be careful not to damage the mating surface.
• Do not insert a screwdriver, this will damage the matingsurfaces.
c. Slide (1) the Tool by tapping (2) its side with a hammer to remove the lower oil pan from the upper oil pan.
3. Remove the oil strainer from the oil pan (upper).
4. Remove the oil pan (upper) using the following steps.
a. Remove the oil pan (upper) bolts a shown.
b. Remove the oil pan (upper) from the cylinder block by prying it at the points shown, using suitable tool.
CAUTION:
Do not damage mating surface.
5. Remove the O-rings from the oil pump and front cover. NOTE:
Do not reuse O-rings.
INSPECTION AFTER REMOVAL
Clean the oil strainer.
INSTALLATION
Tool number : KV10111100 (J-37228)
WBIA0566E
KBIA2467E
KBIA2468E
KBIA2469E
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1. Install the oil pan (upper) using the following steps.
a. Apply liquid gasket thoroughly as shown.
Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-
15, "Recommended Chemical Products and Sealants".
CAUTION:
Apply liquid gasket to outside of bolt hole for the hole
shown by .
b. Install new O-rings to the oil pump and front cover side.
c. Tighten the bolts in numerical order as shown.
2. Install the oil strainer to the oil pan (upper).
3. Install the oil pan (lower).
a. Apply liquid gasket thoroughly as shown. Use Genuine RTV Silicone Seal ant or equivalent. Refer to
GI-15, "
Recommended Chemical Products and Sealants".
b. Tighten the oil pan (lower) bolts in numerical order as shown.
KBIA2470E
KBIA2469E
M6 × 30 mm (1.18 in) : No. 15, 16
M8 × 25 mm (0.98in) : No. 1, 3, 5, 7, 11, 13
M8 × 45 mm (1.77 in) : No. 2, 4, 6, 8, 10, 14
M8 × 123 mm (4.84in) : No. 9, 12
PBIC2553E
KBIA2471E
PBIC2595E
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EM-36
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OIL PAN AND OIL STRAINER
4. Install the oil pan drain plug.
5. Install engine assembly. Refer to EM-78, "
Removal and Installation".
• Do not fill the engine oil for at least 30 minutes after oil pan is installed.
INSPECTION AFTER INSTALLATION
1. Check engine oil level and add engine oil if necessary. Refer to LU-8, "Inspection".
2. Start the engine, and check for leaks of engine oil.
3. Stop engine and wait for 10 minutes.
4. Check engine oil level again.
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IGNITION COILEM-37
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IGNITION COIL
Removal and InstallationINFOID:0000000001538817
REMOVAL
1. Remove the engine room cover using power tool. Refer to
EM-24, "Removal and Installation" .
2. Disconnect the harness connector from the ignition coil.
3. Remove the ignition coil. CAUTION:
Do not shock ignition coil.
INSTALLATION
Installation is in the reverse order of removal.
1. Ignition coil 2. Spark plug
WBIA0796E
Revision: March 2010 2008 QX56