Nissan Pathfinder. Manual — part 548
EXHAUST MANIFOLD AND THREE WAY CATALYST
EM-31
< REMOVAL AND INSTALLATION >
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EXHAUST MANIFOLD AND THREE WAY CATALYST
Exploded View
INFOID:0000000009177904
Removal and Installation (bank 2)
INFOID:0000000009177905
REMOVAL
WARNING:
• Perform the work when the exhaust system has completely cooled down.
• When removing the front and rear engine mount through bolts and nuts, lift the engine up slightly for
safety.
NOTE:
When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spill-
ing.
1.
Gasket
2.
Exhaust manifold (bank 1)
3.
Exhaust manifold cover (bank 1)
4.
Air fuel ratio sensor 1 (bank 1)
5.
Ring gasket
6.
Three way catalyst (bank 1)
7.
Three way catalyst support (bank 1)
8.
Heated oxygen sensor 2 (bank 1)
9.
Three way catalyst (bank 2)
10. Three way catalyst support (bank 2)
11. Heated oxygen sensor 2 (bank 2)
12.
Ring gasket
13. Exhaust manifold (bank 2)
14. Exhaust manifold cover (bank 2)
15.
Air fuel ratio sensor 1 (bank 2)
A.
To oil pan (upper)
B.
Upper mark
AWBIA1356ZZ
EM-32
< REMOVAL AND INSTALLATION >
EXHAUST MANIFOLD AND THREE WAY CATALYST
1. Remove the air cleaner case (upper), air cleaner case (lower), and air duct hose and resonator assembly.
EM-24, "Removal and Installation"
2. Remove the battery and battery tray assembly. Refer to
PG-92, "Removal and Installation"
3. Remove transaxle breather tube. Refer to
TM-196, "Removal and Installation"
4. Remove the front wheels and tires using a power tool. Refer to
5. Remove the engine under cover. Refer to
.
6. Remove the fender protector side covers (LH and RH). Refer to
7. Remove the fan shroud and motor assembly. Refer to
CO-17, "Removal and Installation"
8. Remove the radiator assembly. Refer to
CO-15, "Removal and Installation"
.
9. Remove the front exhaust tube. Refer to
10. Support the engine with a suitable tool.
11. Remove the engine mount bracket (front). Refer to
(2WD) or
12. Remove the three way catalyst support (bank 2).
13. Remove heated oxygen sensor 2 (bank 2), 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 sensor and air fuel ratio (A/F) sensor 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.
14. Remove exhaust manifold and three way catalyst heat shields with power tool.
15. Remove the three way catalyst (bank 2) by loosening the bolts first and then removing the nuts and
through bolts.
16. Loosen and remove the exhaust manifold nuts (bank 2) in the
reverse order as shown.
NOTE:
Number 7 and 8 are not applicable to removal.
17. Remove the exhaust manifold (bank 2) and gasket.
INSPECTION AFTER REMOVAL
Surface Distortion
• Use a reliable straightedge and feeler gauge to check the flatness
of the exhaust manifold mating surfaces.
• Replace the exhaust manifold if the measurement exceeds specifi-
cations.
INSTALLATION
Tool numbers
: KV10114400 (J-38365)
: KV991J0050 (J-44626)
: Engine front
AWBIA1208GB
Limit
: 0.3 mm (0.012 in)
PBIC1173E
EXHAUST MANIFOLD AND THREE WAY CATALYST
EM-33
< REMOVAL AND INSTALLATION >
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Installation is in the reverse order of removal.
1. Install the studs in the exhaust manifold (if removed), and tighten to specification.
2. Install the exhaust manifold gasket in the direction shown.
3. Install the exhaust manifold (bank 2) nuts and tighten to specifi-
cation in the order shown.
NOTE:
Number 7 and 8 are tightened a second time.
CAUTION:
• Before installing a heated oxygen sensor or air fuel ratio (A/F) sensor, clean the exhaust mani-
fold threads using the oxygen sensor thread cleaner tool and apply anti-seize lubricant.
• Do not over-tighten the air fuel ratio (A/F) sensor or heated oxygen sensors. Doing so may cause
damage.
Removal and Installation (bank 1)
INFOID:0000000009177906
REMOVAL
WARNING:
• Perform the work when the exhaust system has completely cooled down.
• When removing the front and rear engine mounting through bolts and nuts, lift the engine up slightly
for safety.
NOTE:
When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spill-
ing.
1. Remove the cowl top grille and the lower cowl top extension. Refer to
2. Remove the right front wheel and tire (4WD models only) using a power tool. Refer to
.
3. Remove the engine under cover. Refer to
.
4. Remove the fender protector side cover (4WD models only). Refer to
.
Exhaust manifold studs
: 15.4 N·m (1.6 kg-m, 11 ft-lb)
(A)
: Bank 1
(B)
: Triangle press
(C)
: Bank 2
: Engine front
PBIC4954E
: Engine front
AWBIA1208GB
Oxygen sensor thread cleaner
: (J-43897-18)
Oxygen sensor thread cleaner
: (J-43897-12)
Tool numbers
: KV10114400 (J-38365)
: KV991J0050 (J-44626)
EM-34
< REMOVAL AND INSTALLATION >
EXHAUST MANIFOLD AND THREE WAY CATALYST
5. Remove transmission air breather hose. Refer to
TM-196, "Removal and Installation"
6. Remove the front exhaust tube, hanger and heat insulator. Refer to
7. Remove the propeller shaft and propeller shaft center bearing (4WD models only). Refer to
8. Remove the RH front axle shaft (4WD models only). Refer to
FAX-18, "Removal and Installation (RH)"
.
9. Remove the RH three way catalyst support brackets.
10. Remove heated oxygen sensor 2 (bank 1), air fuel ratio (A/F) sensor 1 (bank 1).
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.
11. Remove exhaust manifold and three way catalyst heat shields with power tool.
12. Remove the three way catalyst (bank 1) by loosening the bolts first and then removing the nuts and
through bolts.
13. Loosen the exhaust manifold nuts in the reverse order as
shown.
NOTE:
Number 7 and 8 are not applicable to removal.
14. Remove the exhaust manifold (bank 1) and gasket.
INSPECTION AFTER REMOVAL
Surface Distortion
• Use a reliable straightedge and feeler gauge to check the flatness
of the exhaust manifold mating surfaces.
• Replace the exhaust manifold if the measurement exceeds specifi-
cations.
INSTALLATION
Installation is in the reverse order of removal.
1. Install the studs in the exhaust manifold (if removed), and tighten to specification.
Tool numbers
: KV10114400 (J-38365)
: KV991J0050 (J-44626)
: Engine front
AWBIA1209GB
Limit
: 0.3 mm (0.012 in)
PBIC1173E
Exhaust manifold studs
: 15.4 N·m (1.6 kg-m, 11 ft-lb)
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