EXHAUST MANIFOLD INSTALLATION

PROCEDURE


  1. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (TWC: Front Catalyst)


    1. Install a new exhaust manifold to head gasket and a new inlet EGR gasket.

    2. A00Y9Z9E03

      Install the exhaust manifold converter sub-assembly (TWC: Front Catalyst) with 7 new nuts in the order shown in the illustration.

      Torque:
      32 N*m  { 326 kgf*cm, 24 ft.*lbf }

  2. INSTALL MANIFOLD STAY


    1. Install the manifold stay with a new bolt and new nut.

      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 to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) 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 to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) with the 2 nuts and bolt.

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

  5. INSTALL OIL LEVEL DIPSTICK GUIDE SUB-ASSEMBLY


    1. Install a new O-ring to the oil level dipstick guide sub-assembly.

    2. Install the oil level dipstick guide sub-assembly with the bolt.

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

      Tech Tips

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

    3. Install the oil level dipstick sub-assembly.

  6. INSTALL AIR FUEL RATIO SENSOR

    Click here

  7. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)


    1. A00Y9DR

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

      Minimum 41.5 mm (1.63 in.)

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

    2. A00Y6C2C47
      *1 Exhaust Manifold Converter Sub-assembly (TWC: Front Catalyst)
      *2 Gasket
      *a Wooden Block

      Using a plastic hammer and wooden block, tap in the new gasket until each surface is flush with the exhaust manifold converter sub-assembly (TWC: Front Catalyst).

      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 pipes when connecting it.

    3. Install a new gasket to the front exhaust pipe assembly (TWC: Rear Catalyst).

    4. A00Y8O7C07
      *1 Exhaust Manifold Converter Sub-assembly (TWC: Front Catalyst)
      *2 Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
      *3 Gasket
      *a Space between flanges: 8.5 mm (0.335 in.)

      Install the front exhaust pipe assembly (TWC: Rear Catalyst) with the 4 bolts and 2 compression springs.

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

      Tech Tips

      After installation, check that the space between the flanges of the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and front exhaust pipe assembly (TWC: Rear Catalyst) are consistent front-to-rear and left-to-right.

    5. Connect the heated oxygen sensor connector and clamp.

  8. INSPECT FOR EXHAUST GAS LEAK