EXHAUST MANIFOLD INSTALLATION

PROCEDURE


  1. 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 4 bolts.

      Torque:
      13.5 N*m  { 138 kgf*cm, 10 ft.*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 EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (TWC: Front Catalyst)


    1. Install a new exhaust manifold to head 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. Temporarily 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.

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

    5. B00718TN01

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

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

  4. INSTALL AIR FUEL RATIO SENSOR

    Click here

  5. 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 }

  6. INSTALL MANIFOLD STAY


    1. B0071Q2N01

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

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

  7. INSTALL NO. 2 MANIFOLD STAY


    1. B006Z6G

      Tighten the bolt.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
    2. B00712TC01
      *a Torque Wrench Fulcrum Length

      Using a 14 mm union nut wrench, tighten the nut.

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

      Tech Tips


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

        Click here

      • When using a 14 mm union nut wrench (fulcrum length of 25 mm (0.984 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)):

        37.8 N*m (385 kgf*cm, 28 ft.*lbf)

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


    1. B006YJA

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

      Minimum Free Length (Front) 41.5 mm (1.63 in.)
      Minimum Free Length (Rear) 38.5 mm (1.52 in.)

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

    2. Temporarily install 2 new gaskets to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and front exhaust pipe assembly (TWC: Rear Catalyst).

    3. B006X0QC68
      *1 Exhaust Manifold Converter Sub-assembly (TWC: Front Catalyst) or Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
      *2 Gasket
      *a Wooden Block

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

      Note


      • Be sure to install the gasket in the correct direction.

      • Do not reuse the gasket.

      • Do not damage the gasket.

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

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

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

      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.

      B0071HNC18
      *1 Exhaust Manifold Converter Sub-assembly (TWC: Front Catalyst)
      *2 Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
      *3 Gasket
      *a Space between Flanges: 8.5 mm (0.335 in.)

    6. Install the front exhaust pipe assembly (TWC: Rear Catalyst) to the center exhaust pipe assembly with the 2 compression springs and 2 bolts.

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

      Tech Tips

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

      B0071LHC01
      *1 Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
      *2 Center Exhaust Pipe Assembly
      *3 Gasket
      *a Space between Flanges: 6.5 mm (0.256 in.)

    7. Connect the heated oxygen sensor connector.

  9. INSTALL BODY MOUNTING PLATE

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  10. INSTALL CENTER FLOOR CROSSMEMBER BRACE

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  11. INSTALL FRONT CENTER FLOOR BRACE

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  12. INSPECT FOR EXHAUST GAS LEAK

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