EXHAUST MANIFOLD INSTALLATION

PROCEDURE


  1. INSTALL NO. 1 MANIFOLD CONVERTER INSULATOR


    1. Install the No. 1 manifold converter insulator to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) with the 4 bolts.

      Torque:
      13.5 N*m  { 138 kgf*cm, 10 ft.*lbf }
  2. 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:
      13.5 N*m  { 138 kgf*cm, 10 ft.*lbf }
  3. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (TWC: Front Catalyst)


    1. Install a new exhaust manifold to head gasket to the cylinder head sub-assembly.

    2. Temporarily install the exhaust manifold converter sub-assembly (TWC: Front Catalyst) with the 5 nuts.

    3. A0028ZWN06

      Tighten the 5 nuts in the order shown in the illustration.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }
  4. INSTALL AIR FUEL RATIO SENSOR

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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 converter sub-assembly (TWC: Front Catalyst) with the 4 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
  6. INSTALL NO. 2 MANIFOLD STAY


    1. Install the No. 2 manifold stay to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and stiffening crankcase assembly with the bolt and nut.

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


    1. Install the manifold stay to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and stiffening crankcase assembly with the bolt and nut.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
  8. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. A002CBY

      Using a vernier caliper, measure the free length of the 2 compression springs.

      Minimum 41.5 mm (1.63 in.)

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

    2. Temporarily install a new gasket to the exhaust manifold converter sub-assembly (TWC: Front Catalyst).

    3. A0028AXC68
      *1 Exhaust Manifold Converter Sub-assembly (TWC: Front Catalyst)
      *2 Gasket
      *a Wooden Block

      Using a plastic hammer and wooden block, tap in the gasket until its 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 pipe when connecting it.

    4. Install a new gasket to the front exhaust pipe assembly.

    5. A002A3V

      Install the front exhaust pipe assembly with the 2 compression springs and 4 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 converter sub-assembly (TWC: Front Catalyst) and front exhaust pipe assembly is consistent front-to-rear and left-to-right.

      A00278VC02
      *1 Exhaust Manifold Converter Sub-assembly (TWC: Front Catalyst)
      *2 Front Exhaust Pipe Assembly
      *3 Gasket
      *a Space between Flanges: 8.5 mm (0.335 in.)
  9. INSTALL FRONT FLOOR COVER LH


    1. A0027OWC01
      B003ZIE Bolt
      B003Z8F Screw

      Connect the 2 clips (B) to install the front floor cover LH.

    2. Install the clip (A), 2 screws and 4 bolts to the front floor cover LH.

  10. INSTALL NO. 2 ENGINE UNDER COVER

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  11. INSTALL NO. 1 ENGINE UNDER COVER

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  12. INSPECT FOR EXHAUST GAS LEAK

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