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 LH.

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


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

    2. B006MI5N02

      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 }

  3. INSTALL NO. 2 MANIFOLD STAY


    1. Temporarily 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.

    2. B006ON0N03

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

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

  4. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


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

    2. B006PKPN03

      Tighten the 3 bolts in the order shown in the illustration.

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

  5. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE

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

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  7. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. Install a new exhaust pipe 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:
      55 N*m  { 561 kgf*cm, 41 ft.*lbf }

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

    4. Engage the wire harnesses clamp.

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


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

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

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

    Click here

  10. INSTALL EXHAUST MANIFOLD TO HEAD GASKET


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

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


    1. Temporarily install the exhaust manifold sub-assembly RH (TWC: Front Catalyst) to the cylinder head sub-assembly RH with the 6 nuts.

    2. B006QF0N06

      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 }

    3. Engage the 2 wire harness clamps.

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

  12. INSTALL MANIFOLD STAY


    1. B006L8LN01

      Install the manifold stay to the exhaust manifold sub-assembly RH (TWC: Front Catalyst) and transverse engine mounting bracket with the 2 bolts and nut in the order shown in the illustration.

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

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


    1. B006NJX

      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 the minimum, replace the compression spring.

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

    3. B006LAOC68
      *1 Front No. 3 Exhaust Pipe Sub-assembly
      *2 Exhaust Pipe Gasket
      *a Wooden Block

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

      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 pipes when connecting them.

    4. Install 2 new exhaust pipe 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. B006NGN

      Tighten the 4 bolts and 2 nuts.

      Torque:
      Bolt
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
      Nut
      55 N*m  { 561 kgf*cm, 41 ft.*lbf }

      Tech Tips

      After installation, check that the space between the flanges of the exhaust forked pipe sub-assembly (TWC: Rear Catalyst) and front No. 3 exhaust pipe sub-assembly is consistent front-to-rear and left-to-right.

      B006PGAC27
      *1 Exhaust Forked Pipe Sub-assembly (TWC: Rear Catalyst)
      *2 Front No. 3 Exhaust Pipe Sub-assembly
      *3 Exhaust Pipe Gasket
      *a Space between Flanges: 8.5 mm (0.335 in.)

    7. Engage the wire harness clamp.

    8. Connect the heated oxygen sensor grommet to the vehicle body.

  14. CONNECT HEATED OXYGEN SENSOR CONNECTOR (for Bank 1)

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  15. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY (for Separate Console Box Type)

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  16. INSTALL INSTRUMENT PANEL BOX ASSEMBLY (for Separate Console Box Type)

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  17. INSTALL CENTER NO. 2 INSTRUMENT CLUSTER FINISH PANEL (for Separate Console Box Type)

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  18. INSTALL CENTER NO. 1 INSTRUMENT CLUSTER FINISH PANEL (for Separate Console Box Type)

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  19. INSTALL CONSOLE BOX ASSEMBLY (for Integrated Console Box Type)

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  20. INSTALL RADIATOR ASSEMBLY

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  21. INSPECT FOR EXHAUST GAS LEAK

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