EXHAUST MANIFOLD INSTALLATION

PROCEDURE


  1. INSTALL INLET EGR GASKET


    1. A01VKJ2E02
      Text in Illustration
      *a Protrusion

      Install a new inlet EGR gasket to the cylinder head sub-assembly.

      Tech Tips

      Install the inlet EGR gasket so its protrusion is facing the bottom of the engine.

  2. INSTALL EXHAUST MANIFOLD TO HEAD GASKET


    1. A01VIJIE02
      Text in Illustration
      *a Protrusion

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

      Tech Tips

      Install the exhaust manifold to head gasket so its protrusion is facing the rear of the engine.

  3. INSTALL NO. 1 MANIFOLD CONVERTER INSULATOR


    1. Install the No. 1 manifold converter insulator to the exhaust manifold with the 3 bolts.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  4. INSTALL EXHAUST MANIFOLD


    1. A01VJ62E13
      Text in Illustration
      *1 Exhaust Manifold
      *2 Exhaust Pipe Gasket
      *a Wooden Block
      *b Plastic Hammer

      Using a plastic hammer and a wooden block, tap in a new exhaust pipe gasket until its surface is flush with the exhaust manifold.

      Note


      • Install the exhaust pipe gasket in the correct direction.

      • Do not reuse the exhaust pipe gasket.

      • Do not damage the exhaust pipe gasket by dropping it, etc.

      • Do not damage the outer surface of the exhaust pipe gasket.

      • Do not push in the exhaust pipe gasket with the front exhaust pipe assembly when connecting it.

    2. A01VL7PE02

      Temporarily install the exhaust manifold to the cylinder head sub-assembly with the 2 bolts and 4 nuts.

    3. Tighten the 2 bolts and 4 nuts in the order shown in the illustration.

      Torque:
      Bolt and Nut A
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }
      Nut B
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

  5. INSTALL MANIFOLD STAY


    1. A01VJ7LE02

      Temporarily install the manifold stay to the exhaust manifold and cylinder block sub-assembly with the bolt and nut.

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

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

  6. INSTALL HEATED OXYGEN SENSOR

    Click here

  7. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. A01VHU2

      Inspect the free length.

      Free Length of Compression Spring
      Standard Length Minimum Length
      43 mm (1.69 in.) 41.5 mm (1.63 in.)

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

        If the length is not as specified, replace the compression spring.

    2. A01VF4IE06
      Text in Illustration
      *1 Exhaust Manifold
      *2 Front Exhaust Pipe Assembly
      *3 Exhaust Pipe Gasket
      *a Space between flanges: 8.5 mm (0.335 in.)

      Install the front exhaust pipe assembly to the exhaust manifold with the 2 compression springs and 2 bolts.

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

      Note

      After the installation, check that the gaps between the flanges of the exhaust manifold and front exhaust pipe assembly are consistent front-to-rear and left-to-right.

    3. Engage the 3 clamps to connect the No. 2 heated oxygen sensor wire to the fan shroud.

    4. Connect the No. 2 heated oxygen sensor connector.

  8. INSPECT FOR EXHAUST GAS LEAK