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 5 new nuts and the 3 bolts.

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

      

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

      Torque:

      Type A

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

      Type B

      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 DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY

   
   

   1. Install the 2 drive shaft heat insulator sub-assemblies with the 2 nuts.

      Torque:

      17.6 N*m  { 179 kgf*cm, 13 ft.*lbf }

4. 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 the minimum, replace the compression spring.

   2. Temporarily install 2 new gaskets to the exhaust manifold and front exhaust pipe assembly (TWC: Front and Rear Catalyst).

   3. 

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

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

      Note

      
      

      • Be sure to install the gasket in the correct direction.

      • Do not reuse the gaskets.

      • Do not damage the gaskets.

      • Do not push in the gaskets by using the exhaust pipes when connecting them.

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

   5. 

      *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 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 exhaust manifold and front exhaust pipe assembly (TWC: Front and Rear Catalyst) are consistent front-to-rear and left-to-right.

   6. 

      *1	Front Exhaust Pipe Assembly (TWC: Front and Rear Catalyst)
      *2	Center 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 center 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 center exhaust pipe assembly are consistent front-to-rear and left-to-right.

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

5. INSTALL FRONT CENTER FLOOR BRACE

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6. 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 }

7. INSTALL WIRE HARNESS CLAMP BRACKET

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8. INSTALL AIR FUEL RATIO SENSOR

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9. INSPECT FOR EXHAUST GAS LEAK

10. INSTALL NO. 2 ENGINE UNDER COVER

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11. INSTALL NO. 1 ENGINE UNDER COVER (for Half Cover Type)

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12. INSTALL NO. 1 ENGINE UNDER COVER (for Metal Type)

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