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HOMESERVICE MANUALSTOYOTA2004MATRIX XR, FWD, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1051 (EMISSION CONTROL SYSTEM)THREE-WAY CATALYTIC CONVERTER (TWC) SYSTEMREPLACEMENT
2004 Toyota Matrix XR, FWD, Standard

Three-Way Catalytic Converter (TWC) System: Replacement

2004 Toyota Matrix XR, FWD, StandardSECTION Replacement
WARNING: This page is about a different car, the 2004 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Check if an old gasket still remains on the pipe. If so, remove it. Also, check if any bolts or nuts are rusted. If so, replace them.
  1. REMOVE FRONT EXHAUST PIPE 
    1. Remove the 2 bolts and 2 compression springs.
    2. Remove the 2 bolts and exhaust pipe.
    3. Remove the exhaust pipe's gasket and exhaust manifold's gasket.
  2. REMOVE CENTER EXHAUST PIPE 
    1. Remove the heated oxygen sensor (bank 1 sensor 2).
    2. Remove the 2 bolts from the exhaust pipe.
    3. Remove the exhaust pipe from the 2 rings.
    4. Remove the gasket from the exhaust pipe.
  3. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Disconnect the A/F sensor connector (bank 1 sensor 1).
    2. Remove the 3 bolts, nut and No. 1 exhaust manifold heat insulator.
    3. Remove the A/F sensor (bank 1 sensor 1) from the exhaust manifold.
  4. REMOVE EXHAUST MANIFOLD (w/TWC) 
    1. Remove the 2 bolts, 2 nuts and 2 exhaust manifold stays.
    2. Remove the 5 nuts and exhaust manifold,
    3. Remove the gasket from the cylinder head,
  5. INSPECT EXHAUST MANIFOLD (w/ TWC) 

    Using a precision straight edge and feeler gauge, measure the manifold surface contacting the cylinder head for warpage.

    Maximum warpage: 0.70 mm (0.0276 in.) 

    If the warpage is greater than the maximum, replace the manifold.

  6. REMOVE HEAT INSULATORS 
    1. Remove the 3 bolts and No. 1 manifold converter heat insulator.
    2. Remove the 2 bolts and No. 2 manifold converter heat insulator.
    3. Remove the 2 bolts and No. 2 exhaust manifold heat insulator.
  7. INSTALL HEAT INSULATORS 
    1. Install the No. 2 exhaust manifold heat insulator with the 2 bolts.

      Torque: 12 N.m (122 kgf.cm, 9 ft.lbf) 

    2. Install the No. 2 exhaust converter heat insulator with the 2 bolts.

      Torque: 12 N.m (122 kgf.cm, 9 ft.lbf) 

    3. Install the No. 1 manifold converter heat insulator with the 3 bolts.

      Torque: 12 N.m (122 kgf.cm, 9 ft.lbf) 

  8. INSTALL EXHAUST MANIFOLD (w/ TWC) 
    1. Install a new gasket to the cylinder head.
    2. Install the exhaust manifold with the 5 nuts. Uniformly tighten the 5 nuts in the order.

      Torque: 37 N.m (377 kgf.cm, 27 ft.lbf) 

    3. Install the 2 exhaust manifold stays with the 2 bolts and 2 nuts.

      Torque: 44 N.m (449 kgf.cm, 32 ft.lbf) 

  9. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Install the A/F sensor (bank 1 sensor 1) to the exhaust manifold.

      Torque: 44 N.m (449 kgf.cm, 32 ft.lbf) 

    2. Install the No. 1 exhaust manifold heat insulator with the 3 bolts and nut.

      Torque: 12 N.m (122 kgf.cm, 9 ft.lbf) 

    3. Connect the A/F sensor connector (bank 1 sensor 1).
  10. INSTALL CENTER EXHAUST PIPE 
    1. Install a new gasket to the exhaust pipe.
      NOTE:
      • Do not reuse the gasket.
      • The gasket must be installed to the exhaust pipe before the pipe is installed to the tailpipe. Do not indirectly use the tailpipe to force the gasket onto the exhaust pipe.
    2. Install the exhaust pipe to the 2 rings.
    3. Install the 2 bolts to the exhaust pipe.

      Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) 

    4. Install the heated oxygen sensor (bank 1 sensor 2).

      Torque: 44 N.m (449 kgf.cm, 32 ft.lbf) 

    HINT:

    • Before installing the heated oxygen sensor, twist the sensor wire counterclockwise 3 and 1/2 turns.
    • After installing the heated oxygen sensor, check that the sensor wire is not twisted. If it is twisted, remove the heated oxygen sensor and reinstall it.
  11. INSTALL FRONT EXHAUST PIPE 
    1. Using a vernier caliper, measure the free length of the compression spring.
      Fig 1: Measuring Free Length Of Compression Spring Using Vernier Caliper
      G02639352Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Minimum length: 40 mm (1.57 in.) 

      If the free length is less than the minimum, replace the compression spring.

    2. Install a new gasket to the front exhaust pipe.
      NOTE:
      • Do not reuse the gasket.
      • The gasket must be installed to the front exhaust pipe before the pipe is installed to the center exhaust pipe. Do not indirectly use the center exhaust pipe to force the gasket onto the front exhaust pipe.
    3. Install a new gasket to the exhaust manifold.
      Fig 2: Installing Gasket To Exhaust Manifold
      G02639353Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.