EXHAUST MANIFOLD INSTALLATION

PROCEDURE

1. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

   
   

   1. Install the No. 2 exhaust manifold heat insulator to the exhaust manifold with the 3 bolts.

      Torque:

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

2. INSTALL EXHAUST MANIFOLD

   
   

   1. Install a new exhaust manifold to head gasket.

   2. Temporarily install the exhaust manifold and manifold stay with the 5 nuts and 3 bolts.

      Tech Tips

      The type B and type C are non-reusable.

   3. Tighten the exhaust manifold with the 5 nuts in the order shown in the illustration.

      

      *A	Type A	*B	Type B
      *C	Type C	-	-
      *a	18 mm (0.709 in.)	*b	17 mm (0.669 in.)

      Torque:

      Type A

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

      Type B

      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

      Type C

      26 N*m  { 265 kgf*cm, 19 ft.*lbf }

   4. 

      Tighten the 3 bolts.

      Torque:

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

3. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Front and Rear Catalyst)

   
   

   1. 

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

      Minimum (front)	41.5 mm (1.63 in.)
      Minimum (rear)	38.5 mm (1.52 in.)

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

   2. 

      *1	Exhaust Manifold
      *2	Gasket
      *a	Wooden Block

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

      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.

   3. Connect the front exhaust pipe assembly (TWC: Front and Rear Catalyst) to the 2 exhaust pipe supports.

   4. 

      *1	Exhaust Manifold
      *2	Front Exhaust Pipe Assembly (TWC: Front and Rear Catalyst)
      *3	Gasket
      *a	Space Between Flanges: 8.5 mm (0.335 in.)

      Install the front exhaust pipe assembly (TWC: Front and Rear Catalyst) to the exhaust manifold with the 2 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 and front exhaust pipe assembly (TWC: Front and Rear Catalyst) is consistent front-to-rear and left-to-right.

   5. 

      *1	Front Exhaust Pipe Assembly (TWC: Front and Rear Catalyst)
      *2	Gasket
      *a	Wooden Block

      Using a plastic hammer and wooden block, tap in a new gasket until its surface is flush with the front exhaust pipe assembly (TWC: Front and Rear 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 them.

   6. 

      *1	Front Exhaust Pipe Assembly (TWC: Front and Rear Catalyst)
      *2	Tail Exhaust Pipe Assembly
      *3	Gasket
      *a	Space Between Flanges: 6.5 mm (0.256 in.)

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

      Torque:

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

      Tech Tips

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

   7. Connect the heated oxygen sensor connector and wire harness clamp.

4. INSTALL FRONT CENTER FLOOR BRACE SUB-ASSEMBLY

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5. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

   
   

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

      Torque:

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

6. INSTALL WIRE HARNESS CLAMP BRACKET

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7. INSTALL AIR FUEL RATIO SENSOR

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8. INSPECT FOR EXHAUST GAS LEAK

9. INSTALL FRONT NO. 3 ENGINE UNDER COVER (for Full Cover Type)

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10. INSTALL NO. 1 ENGINE UNDER COVER (for Full Cover Type)

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