EXHAUST MANIFOLD INSTALLATION

PROCEDURE


  1. INSTALL EXHAUST MANIFOLD TO HEAD GASKET LH


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

  2. INSTALL AIR FUEL RATIO SENSOR (for Bank 1)

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  3. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH (TWC: Front Catalyst).


    1. Temporarily install the exhaust manifold sub-assembly LH (TWC: Front Catalyst) with the 6 nuts.

    2. A002AL2N02

      Using a 12 mm deep socket wrench, tighten the 6 nuts in the order shown in the illustration.

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

  4. INSTALL NO. 2 MANIFOLD STAY


    1. A002CPAN03

      Install the No. 2 manifold stay to the exhaust manifold sub-assembly LH (TWC: Front Catalyst) and cylinder block sub-assembly with the bolt and nut in the order shown in the illustration.

      Torque:
      34 N*m  { 347 kgf*cm, 25 ft.*lbf }

  5. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the No. 2 exhaust manifold heat insulator to the exhaust manifold sub-assembly LH (TWC: Front Catalyst) with the 3 bolts.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  6. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE

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  7. INSTALL AIR FUEL RATIO SENSOR (for Bank 2)

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  8. INSTALL FRONT EXHAUST PIPE ASSEMBLY


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

    2. Install the front exhaust pipe assembly to the exhaust manifold sub-assembly LH (TWC: Front Catalyst) with the 2 nuts.

      Torque:
      56 N*m  { 571 kgf*cm, 41 ft.*lbf }

    3. Connect the heated oxygen sensor (for Bank 2) connector.

    4. Engage the 3 wire harnesses clamps.

  9. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET (for Lower Side)


    1. Install the No. 1 exhaust pipe support bracket with the 2 bolts.

      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }

  10. INSTALL EXHAUST MANIFOLD TO HEAD GASKET


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

  11. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH (TWC: Front Catalyst)


    1. Using a 12 mm deep socket wrench, install the exhaust manifold sub-assembly RH (TWC: Front Catalyst) with the 6 nuts.

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

    2. Engage the wire harness clamp.

    3. Connect the air fuel ratio sensor (for Bank 1) connector.

  12. INSTALL MANIFOLD STAY


    1. Install the manifold stay to the exhaust manifold sub-assembly RH (TWC: Front Catalyst) and automatic transaxle assembly with bolt and nut.

      Torque:
      Bolt
      34 N*m  { 347 kgf*cm, 25 ft.*lbf }
      Nut
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

  13. INSTALL FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY


    1. A002CBY

      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 minimum, replace the compression spring.

    2. Temporarily install a new gasket to the front No. 3 exhaust pipe sub-assembly (center exhaust pipe assembly (TWC: Rear Catalyst) side).

    3. A0028AXC68
      *1 Front No. 3 Exhaust Pipe Sub-assembly
      *2 Gasket
      *a Wooden Block

      Using a plastic hammer and wooden block, tap in the gasket until its surface is flush with the front No. 3 exhaust pipe sub-assembly.

      Note


      • Be careful with the installation direction of the gasket.

      • 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 2 new gaskets to the front No. 3 exhaust pipe sub-assembly.

    5. Temporarily install the front No. 3 exhaust pipe sub-assembly with the 4 bolts, 2 nuts and 2 compression springs.

    6. Tighten the 2 bolts and 2 nuts.

      Torque:
      56 N*m  { 571 kgf*cm, 41 ft.*lbf }

    7. Tighten 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 center exhaust pipe assembly (TWC: Rear Catalyst) and front No. 3 exhaust pipe sub-assembly is consistent front-to-rear and left-to-right.

      A00274DC27
      *1 Center Exhaust Pipe Assembly (TWC: Rear Catalyst)
      *2 Front No. 3 Exhaust Pipe Sub-assembly
      *3 Gasket
      *a Space between Flanges: 8.5 mm (0.335 in.)

    8. Connect the heated oxygen sensor (for Bank 1) connector.

    9. Engage the 4 wire harness clamps.

  14. TEMPORARILY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 4WD)

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  15. FULLY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 4WD)

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  16. INSTALL FRONT FLOOR COVER LH


    1. A0027OWC01
      B003ZIE Bolt
      B003Z8F Screw

      Install the front floor cover LH with the 2 clips (B).

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

  17. INSTALL NO. 2 ENGINE UNDER COVER

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  18. INSTALL RADIATOR ASSEMBLY

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  19. INSPECT FOR EXHAUST GAS LEAK

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