EXHAUST MANIFOLD INSTALLATION

PROCEDURE


  1. INSTALL STUD BOLT

    Tech Tips

    If a stud bolt is deformed or the threads are damaged, replace it.


    1. A01W1QP

      Using an E8 "TORX" socket wrench, install the stud bolt to the exhaust manifold converter sub-assembly (TWC: Front Catalyst).

      Torque:
      9.5 N*m  { 97 kgf*cm, 84 in.*lbf }

  2. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the No. 2 exhaust manifold heat insulator to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) with the 2 bolts.

      Torque:
      13.5 N*m  { 138 kgf*cm, 10 ft.*lbf }

  3. INSTALL NO. 1 MANIFOLD CONVERTER INSULATOR


    1. Install the No. 1 manifold converter insulator to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) with the 3 bolts.

      Torque:
      13.5 N*m  { 138 kgf*cm, 10 ft.*lbf }

  4. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (TWC: Front Catalyst)


    1. Install a new exhaust manifold gasket to the cylinder head sub-assembly.

    2. Temporarily install the exhaust manifold converter sub-assembly (TWC: Front Catalyst) to the cylinder head sub-assembly with the 5 nuts.

    3. Install 2 new EGR cooler gaskets to the EGR pipe connector.

    4. Temporarily install the EGR pipe connector to the exhaust manifold converter sub-assembly (TWC: Front Catalyst), EGR cooler assembly and cylinder block sub-assembly with the 4 bolts and nut.

    5. A01W17TE02

      Tighten the 5 nuts in the order shown in the illustration.

      Torque:
      62 N*m  { 632 kgf*cm, 46 ft.*lbf }
    6. A01W2BOE03
      Text in Illustration
      *a Bolt (A)
      *b Bolt (B)
      B001O8N Bolt
      B001OAO Nut

      Tighten the 4 bolts and nut.

      Torque:
      Bolt (A) and Nut
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }
      Bolt (B)
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  5. INSTALL NO. 2 MANIFOLD STAY


    1. Install the No. 2 manifold stay to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and stiffening crankcase assembly with the bolt and nut.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  6. INSTALL MANIFOLD STAY


    1. Install the manifold stay to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and stiffening crankcase assembly with the bolt and nut.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  7. INSTALL AIR FUEL RATIO SENSOR

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  8. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the No. 1 exhaust manifold heat insulator to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) with the 4 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  9. INSTALL INLET AIR CLEANER ASSEMBLY

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  10. INSTALL COOL AIR INTAKE DUCT SEAL

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  11. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)


    1. A01W54NE03

      Using a vernier caliper, measure the free length of the 2 compression springs.

      Minimum Free Length 40.5 mm (1.59 in.)

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

    2. Temporarily install a new exhaust pipe gasket to the exhaust manifold converter sub-assembly (TWC: Front Catalyst).

    3. A01VZGDE50
      Text in Illustration
      *1 Exhaust Manifold Converter Sub-assembly (TWC: Front Catalyst)
      *2 Exhaust Pipe Gasket
      *a Wooden Block

      Using a plastic hammer and wooden block, tap in the exhaust pipe gasket until its surface is flush with the exhaust manifold converter sub-assembly (TWC: Front Catalyst).

      Note


      • Be careful with the installation direction of the exhaust pipe gasket.

      • Do not reuse the exhaust pipe gasket.

      • Do not damage the exhaust pipe gasket.

      • Do not push in the exhaust pipe gasket by using the exhaust pipe when connecting it.

    4. Install a new exhaust pipe gasket to the front exhaust pipe assembly (TWC: Rear Catalyst).

    5. Connect the front exhaust pipe assembly (TWC: Rear Catalyst) to the exhaust pipe support.

    6. Install the front exhaust pipe assembly (TWC: Rear Catalyst) to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and center exhaust pipe assembly with the 2 compression springs, 2 bolts and 2 nuts.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

      Tech Tips

      After installation, check that the space between the flanges of the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and front exhaust pipe assembly (TWC: Rear Catalyst) is consistent front-to-rear and left-to-right.

      A01W5BEE01
      Text in Illustration
      *1 Exhaust Manifold Converter Sub-assembly (TWC: Front Catalyst)
      *2 Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
      *3 Exhaust Pipe Gasket
      *a Space between Flanges: 8.5 mm (0.335 in.)

    7. Connect the heated oxygen sensor connector.

  12. INSPECT FOR EXHAUST GAS LEAK

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  13. INSTALL ENGINE UNDER COVER LH

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  14. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH

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  15. INSTALL ENGINE UNDER COVER RH

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  16. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH

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