EXHAUST MANIFOLD INSTALLATION

PROCEDURE


  1. INSTALL NO. 1 MANIFOLD CONVERTER INSULATOR


    1. Install the No. 1 manifold converter insulator onto the exhaust manifold converter sub-assembly with the 2 bolts.

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

  2. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    1. Install the new exhaust manifold to head gasket and inlet EGR gasket onto the cylinder head sub-assembly.

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

    3. A01VJL1E02

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

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

  3. INSTALL MANIFOLD STAY


    1. Temporarily install the manifold stay with the 2 bolts.

    2. A01VJY2E02

      Tighten the 2 bolts in the order shown in the illustration.

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

  4. INSTALL EGR INLET EXHAUST MANIFOLD PLATE


    1. Install the EGR inlet exhaust manifold plate onto the No. 1 water by-pass pipe with the 2 bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

  5. INSTALL HEATED OXYGEN SENSOR

    Click here

  6. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. A01VHU2

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

      Minimum Length
      41.5 mm (1.634 in.)

      Tech Tips

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

    2. A01VG3XE12
      Text in Illustration
      *1 Exhaust Pipe Gasket
      *2 Wooden Block

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

      Note


      • Install the gasket in the correct direction.

      • Do not reuse the gasket.

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

      • Do not damage the outer surface of the gasket.

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

    3. A01VJRBE01
      Text in Illustration
      *1 Exhaust Manifold Converter Sub-assembly
      *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 converter sub-assembly 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.

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

    5. Connect the connector of the No. 2 heated oxygen sensor.

  7. INSPECT FOR EXHAUST GAS LEAK