EXHAUST MANIFOLD INSTALLATION

PROCEDURE


  1. INSTALL STUD BOLT

    Tech Tips

    If a stud bolt is deformed or its threads are damaged, replace it.


    1. A0029ZL

      Using an E8 "TORX" socket wrench, install the 2 stud bolts to the exhaust manifold (TWC: Front Catalyst).

      Torque:
      19.5 N*m  { 199 kgf*cm, 14 ft.*lbf }
    2. A002AW8

      Using an E8 "TORX" socket wrench, install the 2 stud bolts to the exhaust manifold assembly LH (TWC: Front Catalyst).

      Torque:
      19.5 N*m  { 199 kgf*cm, 14 ft.*lbf }

  2. INSTALL EXHAUST MANIFOLD TO HEAD GASKET (for Bank 2)


    1. Install a new exhaust manifold to head gasket (for Bank 2) to the cylinder head sub-assembly.

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


    1. Temporarily install the exhaust manifold assembly LH (TWC: Front Catalyst) with the 4 nuts.

    2. Temporarily install the No. 2 manifold stay to the exhaust manifold assembly LH (TWC: Front Catalyst) and cylinder block sub-assembly with the bolt and nut.

    3. A002BF4N01

      Using a 12 mm deep socket wrench, tighten the 4 nuts in the order shown in the illustration.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    4. A0029F9C02
      B003ZIE Bolt
      B003Z8F Nut

      Tighten the bolt and nut in the order shown in the illustration.

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

  4. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. A002823N01

      Install the No. 2 exhaust manifold heat insulator to the exhaust manifold assembly LH (TWC: Front Catalyst) with the 3 bolts in the order shown in the illustration.

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

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

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  6. INSTALL V-BANK COVER SUB-ASSEMBLY

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  7. INSTALL FRONT EXHAUST PIPE ASSEMBLY

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

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

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  10. INSTALL EXHAUST MANIFOLD TO HEAD GASKET (for Bank 1)


    1. Install a new exhaust manifold to head gasket (for Bank 1) to the cylinder head sub-assembly RH.

  11. INSTALL EXHAUST MANIFOLD (TWC: Front Catalyst)


    1. Temporarily install the exhaust manifold (TWC: Front Catalyst) with the 4 nuts.

    2. Temporarily install the manifold stay to the exhaust manifold (TWC: Front Catalyst) and rear engine mounting bracket with the bolt and nut.

    3. A002BC7N01

      Using a 12 mm deep socket wrench, tighten the 4 nuts in the order shown in the illustration.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    4. A00280QC03
      B003ZIE Bolt
      B003Z8F Nut

      Tighten the bolt and nut in the order shown in the illustration.

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

    5. Engage the 3 wire harness clamps.

    6. Connect the air fuel ratio sensor connector.

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


    1. A002CBY

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

      Standard Length 43.0 mm (1.69 in.)
      Minimum Free Length 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 pipes when connecting them.

    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:
      43 N*m  { 438 kgf*cm, 32 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 3 wire harness clamps.

  13. INSPECT FOR EXHAUST GAS LEAK

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  14. 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.

  15. INSTALL NO. 2 ENGINE UNDER COVER

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  16. INSTALL NO. 1 ENGINE UNDER COVER

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