EXHAUST MANIFOLD INSTALLATION

PROCEDURE


  1. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    1. A01VHKM

      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 7 new nuts.

    3. A01VKHCE02

      Tighten the 7 nuts in the order shown in the illustration.

      Torque:
      32 N*m  { 326 kgf*cm, 23 ft.*lbf }

  2. INSTALL MANIFOLD STAY


    1. Temporarily install the manifold stay onto the exhaust manifold converter sub-assembly with the bolt and new nut.

    2. A01VLU0E02

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

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  3. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


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

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

  4. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the No. 1 exhaust manifold heat insulator onto the exhaust manifold converter sub-assembly with the 2 nuts and bolt.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  5. INSTALL AIR FUEL RATIO SENSOR

    Click here

  6. INSTALL OIL LEVEL DIPSTICK GUIDE


    1. Install a new O-ring onto the oil level dipstick guide.

    2. Apply engine oil to the O-ring and install the oil level dipstick guide into the oil pan.

    3. Install the oil level dipstick guide onto the cylinder head cover sub-assembly with the bolt.

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

  7. INSTALL OIL LEVEL DIPSTICK SUB-ASSEMBLY

  8. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. A01VJJ8

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

      Minimum length
      41.5 mm (1.634 in.)

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

    2. A01VIW9E06
      Text in Illustration
      *1 Exhaust Pipe Gasket
      *2 Wooden Block
      *3 Plastic Hammer
      *4 Exhaust Manifold Converter Sub-assembly

      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 sub-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 converter sub-assembly and front exhaust pipe assembly are consistent front-to-rear and left-to-right.

    4. Connect the connector of the heated oxygen sensor.

    5. Engage the clamp and connect the heated oxygen sensor wire to the wire harness clamp bracket.

  9. INSPECT FOR EXHAUST GAS LEAK

    Tech Tips

    Perform "Inspection After Repairs" after repairing or replacing the exhaust system Click here.