EXHAUST MANIFOLD INSTALLATION

PROCEDURE


  1. INSTALL AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1)

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  2. INSTALL AIR FUEL RATIO SENSOR (for Bank 2 Sensor 1)

    Click here

  3. INSTALL EXHAUST MANIFOLD ASSEMBLY RH


    1. A01X4IW

      w/ Secondary Air Injection System:

      Install a new gasket to the No. 3 air tube.

      Tech Tips

      Install the gasket with the claws of the gasket facing the tube.

    2. A01XAP0E02
      Text in Illustration
      *1 Tab
      *a Front

      Install a new gasket to the cylinder head.

      Tech Tips

      Install the gasket with the gasket tab facing toward the front of the engine.

    3. w/ Secondary Air Injection System:


      1. A01XBBJE02

        Install the exhaust manifold to the cylinder head with the 7 new nuts labeled A.

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

      2. Install the exhaust manifold to the No. 3 air tube with the 2 nuts labeled B.

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

    4. w/o Secondary Air Injection System:

      Install the exhaust manifold with 7 new nuts.

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

    5. Connect the air fuel ratio sensor connector and attach the wire harness clamp.

  4. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the heat insulator with 3 new bolts.

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

  5. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Apply engine oil to a new O-ring, and then install the O-ring to the engine oil level dipstick guide.

    2. Install the engine oil level dipstick guide with the bolt.

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

    3. Attach the engine wire clamp.

    4. Install the engine oil level dipstick.

  6. INSTALL MANIFOLD STAY


    1. Temporarily install the manifold stay with the 3 bolts.

    2. B001WV3E02

      Tighten the 3 bolts in the sequence shown in the illustration.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  7. INSTALL EXHAUST MANIFOLD ASSEMBLY LH


    1. A01X4IW

      w/ Secondary Air Injection System:

      Install a new gasket to the No. 4 air tube.

      Tech Tips

      Install the gasket with the claws of the gasket facing the tube.

    2. A01X5LOE02
      Text in Illustration
      *1 Tab
      *a Front

      Install a new gasket to the cylinder head.

      Tech Tips

      Install the gasket with the gasket tab facing toward the rear of the engine.

    3. w/ Secondary Air Injection System:


      1. A01XANAE02

        Install the exhaust manifold to the cylinder head with the 7 new nuts labeled A.

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

      2. Install the exhaust manifold to the No. 4 air tube with the 2 nuts labeled B.

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

    4. w/o Secondary Air Injection System:

      Install the exhaust manifold with 7 new nuts.

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

    5. Connect the air fuel ratio sensor connector and attach the wire harness clamp.

  8. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the heat insulator with 3 new bolts.

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

  9. INSTALL NO. 2 MANIFOLD STAY


    1. Temporarily install the manifold stay with the 3 bolts.

    2. A01X3ZRE02

      Tighten the 3 bolts in the sequence shown in the illustration.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  10. INSTALL PROPELLER SHAFT HEAT INSULATOR


    1. Install the propeller shaft heat insulator with the 2 bolts.

      Torque:
      16 N*m  { 160 kgf*cm, 12 ft.*lbf }

  11. INSTALL FRONT PROPELLER SHAFT ASSEMBLY

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  12. INSTALL FRONT EXHAUST PIPE ASSEMBLY

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  13. INSPECT FOR EXHAUST GAS LEAK

    If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.

  14. INSTALL FRONT FENDER APRON TRIM PACKING C


    1. Install the front fender apron trim packing C with the 4 clips.

  15. INSTALL FRONT FENDER APRON TRIM PACKING A


    1. Install the front fender apron trim packing A with the 3 clips.

  16. INSTALL FRONT FENDER APRON TRIM PACKING D


    1. Install the front fender apron trim packing D with the 4 clips.

  17. INSTALL FRONT FENDER APRON TRIM PACKING B


    1. w/ KDSS

      Install the front fender apron trim packing B with the 3 clips.

    2. w/o KDSS

      Install the front fender apron trim packing B with the 4 clips.

  18. INSTALL NO. 2 ENGINE UNDER COVER

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  19. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

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  20. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

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  21. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH

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  22. INSTALL AIR CLEANER AND HOSE

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  23. INSTALL V-BANK COVER SUB-ASSEMBLY

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