EXHAUST MANIFOLD INSTALLATION

PROCEDURE


  1. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the No. 2 exhaust manifold heat insulator with the 2 bolts.

      Torque:
      13.5 N*m  { 138 kgf*cm, 10 ft.*lbf }

  2. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


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

    2. Temporarily install the exhaust manifold converter sub-assembly with the 5 nuts.

    3. Temporarily install the manifold stay and No. 2 manifold stay with the 2 bolts and 2 nuts.

    4. A01H5RT

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

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

  3. INSTALL MANIFOLD STAY


    1. A01H84P

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

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

  4. INSTALL NO. 2 MANIFOLD STAY


    1. A01H80V

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

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

  5. INSTALL NO. 2 EGR PIPE (w/ EGR System)


    1. Install 2 new gaskets to the No. 2 EGR pipe.

      Note

      Make sure the claws of the gasket face the No. 2 EGR pipe.

    2. Install the No. 2 EGR pipe with the 2 bolts and 2 nuts.

      Torque:
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }

  6. INSTALL NO. 1 MANIFOLD CONVERTER INSULATOR


    1. Install the No. 1 manifold converter insulator with the 3 bolts.

      Torque:
      13.5 N*m  { 138 kgf*cm, 10 ft.*lbf }

  7. INSTALL AIR FUEL RATIO SENSOR

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  8. CONNECT INVERTER RESERVE TANK ASSEMBLY

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  9. CONNECT WIRE HARNESS

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  10. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the No. 1 exhaust manifold heat insulator with the 4 bolts.

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

  11. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. A01H6WR

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

      Minimum length
      41.5 mm (1.63 in.)

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

    2. Using a wire brush, remove any foreign matter from the gasket installation surface.

    3. A01H5TXC36
      *1 Exhaust Manifold Converter Sub-assembly
      *2 Gasket
      *a Wooden Block

      Using a plastic-faced hammer and wooden block, tap in a new gasket until its surface is flush with the exhaust manifold converter sub-assembly.

      Note


      • Be sure to install the gasket so that it faces the correct direction.

      • Do not reuse the gasket.

      • Do not damage the gasket.

      • When connecting the front exhaust pipe assembly, do not push in the gasket with the front exhaust pipe assembly.

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

    5. A01H80YC02
      *1 Exhaust Manifold Converter Sub-assembly
      *2 Front Exhaust Pipe Assembly
      *3 Gasket
      *a Space between flanges: 8.5 mm (0.335 in.)

      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 and front exhaust pipe assembly is consistent front-to-rear and left-to-right.

    6. Connect the heated oxygen sensor connector.

  12. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

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  13. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

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  14. INSPECT FOR EXHAUST GAS LEAK

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