EXHAUST MANIFOLD INSTALLATION

PROCEDURE


  1. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the No. 2 exhaust manifold heat insulator to the exhaust manifold (TWC: Front Catalyst) with the 6 bolts.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  2. INSTALL EXHAUST MANIFOLD (TWC: Front Catalyst)


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

    2. Temporarily install the exhaust manifold (TWC: Front Catalyst), No. 1 upper front floor heat insulator and No. 1 exhaust manifold heat insulator.

      Tech Tips

      At this time, do not install the parts with bolts or nuts.

    3. B006Z5IN01

      Using a 12 mm deep socket wrench, temporarily install the exhaust manifold (TWC: Front Catalyst) to the cylinder head sub-assembly with 7 new nuts.

    4. Using the 12 mm deep socket wrench, tighten the 7 nuts in the order shown in the illustration.

      Torque:
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }

  3. INSTALL MANIFOLD STAY


    1. B006ZPLN01

      Temporarily install the manifold stay to the exhaust manifold (TWC: Front Catalyst) and cylinder block sub-assembly with the bolt and nut.

    2. Tighten the bolt and nut in the order shown in the illustration.

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

  4. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. B0071A4C01
      *a Torque Wrench Fulcrum Length

      Using a 10 mm union nut wrench, install the No. 1 exhaust manifold heat insulator to the exhaust manifold (TWC: Front Catalyst) with the 5 bolts.

      Torque:
      Specified tightening torque
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Click here

      • When using a 10 mm union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)): 8.8 N*m (90 kgf*cm, 78 in.*lbf)

  5. INSTALL NO. 1 UPPER FRONT FLOOR HEAT INSULATOR


    1. B0071S1C01
      *a Torque Wrench Fulcrum Length

      Using a 10 mm union nut wrench, install the No. 1 upper front floor heat insulator to the vehicle body with the 2 nuts.

      Torque:
      Specified tightening torque
      4.9 N*m  { 50 kgf*cm, 43 in.*lbf }

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Click here

      • When using a 10 mm union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)): 4.3 N*m (44 kgf*cm, 38 in.*lbf)

  6. INSTALL WIRE HARNESS CLAMP BRACKET


    1. Install the wire harness clamp bracket with the bolt.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  7. INSTALL AIR FUEL RATIO SENSOR (for Sensor 1)

    Click here

  8. INSTALL FRONT CENTER UPPER SUSPENSION BRACE SUB-ASSEMBLY

    Click here

  9. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  10. INSTALL FRONT LOWER NO. 1 FLOOR HEAT INSULATOR

    Click here

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


    1. Install 2 new gaskets to the front exhaust pipe assembly (TWC: Rear Catalyst).

    2. Connect the front exhaust pipe assembly (TWC: Rear Catalyst) to the 2 exhaust pipe supports.

    3. Install the front exhaust pipe assembly (TWC: Rear Catalyst) to the exhaust manifold (TWC: Front Catalyst) and center exhaust pipe assembly with 2 new bolts and 2 new nuts.

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

    4. Connect the air fuel ratio sensor (for sensor 2) connector.

    5. Engage the wire harness clamp.

  12. INSTALL CENTER FLOOR CROSSMEMBER BRACE

    Click here

  13. INSTALL FRONT CENTER FLOOR BRACE

    Click here

  14. INSTALL FRONT FLOOR COVER LH

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  15. INSTALL FRONT FLOOR COVER RH

    Click here

  16. INSPECT FOR EXHAUST GAS LEAK

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  17. INSTALL NO. 2 ENGINE UNDER COVER ASSEMBLY

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  18. INSTALL NO. 1 ENGINE UNDER COVER

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  19. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH

    Click here

  20. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH

    Click here