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 and a new EGR cooler gasket.

    2. Temporarily install the exhaust manifold and manifold stay with the 7 nuts and 3 bolts.

      Tech Tips

      The type B and type C are non-reusable.

    3. Tighten the 7 nuts in the order shown in the illustration.

      A01KRX9C01
      *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. A01KT9M

      Tighten the 3 bolts.

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

  3. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


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

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

  4. INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR


    1. Install the front No. 1 floor heat insulator with the 3 nuts.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  5. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Front and Rear Catalyst) (w/ Exhaust Heat Recirculation System)

    Note

    When installing the water hose, ensure that the exhaust heat recirculation system is filled with coolant. Otherwise, the engine water pump assembly may be damaged.


    1. A01KTDK

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

    3. A01KR7HC47
      *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 new 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 gaskets 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. A01KTP5C17
      *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.)

      Connect 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.

    6. A01KSNWC23
      *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 2 heater water hoses and slide the 2 clips to secure them.

    8. Connect the 3 clamps and oxygen sensor connector.

  6. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Front and Rear Catalyst) (w/o Exhaust Heat Recirculation System)


    1. A01KTDK

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

    3. A01KR7HC47
      *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 new 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 gaskets 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. A01KTP5C17
      *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.)

      Connect 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.

    6. A01KSNWC23
      *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 3 clamps and heated oxygen sensor connector.

  7. INSTALL AIR FUEL RATIO SENSOR

    Click here

  8. ADD ENGINE COOLANT (w/ Exhaust Heat Recirculation System)

    Click here

  9. INSPECT FOR COOLANT LEAK (w/ Exhaust Heat Recirculation System)

    Click here

  10. INSTALL FRONT CENTER FLOOR BRACE SUB-ASSEMBLY

    Click here

  11. INSTALL FRONT NO. 3 ENGINE UNDER COVER

    Click here

  12. INSTALL NO. 1 ENGINE UNDER COVER

    Click here

  13. INSPECT FOR EXHAUST GAS LEAK