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Three-Way Catalytic Converter (TWC) System: Replacement

  1. REMOVE ENGINE COVER 
  2. REMOVE AIR CLEANER INLET 
  3. REMOVE AIR CLEANER ASSEMBLY AND MAF METER (See  REMOVAL  ) 
  4. DISCONNECT HEATED OXYGEN SENSORS (BANK 1 SENSOR 1, 2) FROM EXHAUST MANIFOLD 
    1. Disconnect the 3 oxygen sensor connectors.
    2. Disconnect the 2 oxygen sensors from the exhaust manifold.
  5. REMOVE FRONT EXHAUST PIPE (WITH REAR TWC) 
    1. Take out the front side of the floor carpet.
    2. Disconnect the heated oxygen sensor (bank 2 sensor 2) connector.
    3. Remove the 2 bolts and pipe support bracket.
    4. Remove the 5 bolts, front exhaust pipe and 3 gaskets.
  6. REMOVE EXHAUST MANIFOLD (WITH FRONT TWC) 
    1. Using a 14 mm deep socket wrench, remove the 8 nuts, exhaust manifold and 2 gaskets.
    2. Remove the heated oxygen sensor (bank 2 sensor 1) form the exhaust manifold.
      3. Fig 1: Removing Exhaust Manifold (With Front TWC)
      G02948492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REINSTALL EXHAUST MANIFOLD (WITH FRONT TWC) 
    1. Install the heated oxygen sensor (bank 2 sensor 1) to the exhaust manifold.

      Torque: 45 N.m (450 kgf.cm, 33 ft.lbf) 

    2. Install 2 new gaskets to the cylinder head.
    3. Using a 14 mm deep socket wrench, install a new exhaust manifold with 8 new nuts. Uniformly tighten the nuts in several passes.
      1. Torque: 40 N.m (408 kgf.cm, 30 ft.lbf) 
  8. REINSTALL FRONT EXHAUST PIPE (WITH REAR TWC) 
    1. Reinstall new 3 gaskets and front exhaust pipe with 5 bolts and support bracket.
      1. Torque: 44 N.m (440 kgf.cm, 32 ft.lbf) 
    2. Reinstall the pipe support bracket with the 2 bolts.
      1. Torque: 44 N.m (440 kgf.cm, 32 ft.lbf) 
  9. RECONNECT HEATED OXYGEN SENSORS (BANK 1 SENSOR 1, 2) TO EXHAUST MANIFOLD 
    1. Install the 2 oxygen sensors to the exhaust manifold.
      1. Torque: 45 N.m (450 kgf.cm, 33 ft.lbf) 
    2. Connect the 3 oxygen sensor connectors.
  10. REINSTALL AIR CLEANER ASSEMBLY AND MAF METER (See  INSTALLATION  ) 
  11. REINSTALL AIR CLEANER INLET 
  12. REINSTALL ENGINE COVER 
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