EXHAUST MANIFOLD INSTALLATION

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 }
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. Tighten the 5 nuts in the order shown in the illustration.
  
  Torque:
  
  35 N*m { 357 kgf*cm, 26 ft.*lbf }
INSTALL MANIFOLD STAY
1. Tighten the bolt and nut in the order shown in the illustration.
  
  Torque:
  
  43 N*m { 438 kgf*cm, 32 ft.*lbf }
INSTALL NO. 2 MANIFOLD STAY
1. Tighten the bolt and nut in the order shown in the illustration.
  
  Torque:
  
  43 N*m { 438 kgf*cm, 32 ft.*lbf }
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 }
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 }
INSTALL AIR FUEL RATIO SENSOR
1. Text in Illustration
  
  *a Torque Wrench Fulcrum Length
  
  Using SST, install the air fuel ratio sensor to the exhaust manifold.
  
  SST
  
  09224-00010
  
  Torque:
  
  Specified tightening torque
  
  44 N*m { 449 kgf*cm, 32 ft.*lbf }
  Tech Tips
  - Calculate the torque wrench reading when changing the fulcrum length of the torque wrench Click here.
  - When using SST (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 300 mm (11.8 in.)):
    
    40 N*m (408 kgf*cm, 30 ft.*lbf)
  - 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.
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 }

Text in Illustration
*a	Torque Wrench Fulcrum Length

INSTALL FRONT EXHAUST PIPE ASSEMBLY

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

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.

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

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.

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.)

Connect the heated oxygen sensor connector.

INSTALL ENGINE UNDER COVER LH
INSTALL FRONT WHEEL OPENING EXTENSION PAD LH
INSTALL ENGINE UNDER COVER RH
INSTALL FRONT WHEEL OPENING EXTENSION PAD RH
INSPECT FOR EXHAUST GAS LEAK

If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.
1. Perform "Inspection After Repair" after repairing an exhaust gas leak Click here.

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