EXHAUST MANIFOLD INSTALLATION


  1. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the No. 2 exhaust manifold heat insulator with the 2 bolts.

      Torque:
      14 N*m  { 138 kgf*cm, 10 ft.*lbf }

  2. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    1. Set a new gasket to the cylinder head sub-assembly.

    2. Temporarily install the exhaust manifold converter sub-assembly with the 5 nuts.

    3. Temporarily install the No. 2 manifold stay and manifold stay with the 2 bolts and 2 nuts.

    4. A01HU5UE04

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

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

  3. INSTALL MANIFOLD STAY


    1. A01HW2ZE01

      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. 2 MANIFOLD STAY


    1. A01HTM5E01

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

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

  5. INSTALL NO. 2 EGR PIPE


    1. Install 2 new gaskets to the No. 2 EGR pipe.

    2. Install the No. 2 EGR pipe with the 2 bolts and 2 nuts.

      Torque:
      36 N*m  { 367 kgf*cm, 26 ft.*lbf }

  6. INSTALL NO. 1 MANIFOLD CONVERTER INSULATOR


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

      Torque:
      14 N*m  { 138 kgf*cm, 10 ft.*lbf }

  7. INSTALL AIR FUEL RATIO SENSOR


    1. A01HW7FE01
      Text in Illustration
      *a

      Fulcrum Length

      30 mm
      *b

      Fulcrum Length

      300 mm

      Using SST, install the air fuel ratio sensor to the exhaust manifold.

      SST
      09224-00010
      Torque:
      without SST
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }
      with SST
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

      Note


      • The "with SST" torque value is effective when using SST with a fulcrum length of 30 mm (1.18 in.) and a torque wrench with a fulcrum length of 300 mm (11.81 in.) Click here.

      • The "with SST" torque value is effective when SST is parallel to the torque wrench.

      Tech Tips

      Perform "Inspection After Repair" after replacing the air fuel ratio sensor Click here.

    2. Connect the air fuel ratio sensor connector.

    3. Install the hose clamp.

  8. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the No. 1 exhaust manifold heat insulator with the 4 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  9. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. A01HUKEE03

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

      Standard 42.0 mm (1.65 in.)
      Minimum 40.5 mm (1.60 in.)

      Tech Tips

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

    2. Fully insert a new gasket to the exhaust manifold converter sub-assembly.

    3. A01HSQ3E14
      Text in Illustration
      *1 Exhaust Manifold Converter Sub-assembly
      *2 Wooden Block
      *3 Gasket

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

      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. Install a new gasket to the front exhaust pipe assembly.

    5. Connect the front exhaust pipe assembly to the exhaust pipe support.

    6. Install the front exhaust pipe assembly with the 2 compression springs, 2 bolts and 2 nuts.

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

      Tech Tips

      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.

      A01HV63E01
      Text in Illustration
      *1 Exhaust Manifold Converter Sub-assembly
      *2 Front Exhaust Pipe Assembly
      *3 Gasket
      *a Space between flanges: 8.5 mm (0.335 in.)

    7. Connect the heated oxygen sensor connector.

  10. INSTALL ENGINE UNDER COVER LH

  11. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH

  12. INSTALL ENGINE UNDER COVER RH

  13. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH

  14. INSPECT FOR EXHAUST GAS LEAK