EXHAUST MANIFOLD INSTALLATION

PROCEDURE


  1. INSTALL STUD BOLT

    Tech Tips

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


    1. B006PVV

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

      Torque:
      19.5 N*m  { 199 kgf*cm, 14 ft.*lbf }
    2. B006M7R

      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. B006NIPN01

      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. B006KR2C02
      B006QOD Bolt
      B006LKF Nut

      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. B006MEZN01

      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)

    Click here

  6. INSTALL V-BANK COVER SUB-ASSEMBLY

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  7. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)


    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:
      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 (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 ASSEMBLY RH (TWC: Front Catalyst)


    1. Temporarily install the exhaust manifold assembly RH (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 2 bolts and nut.

    3. B006L1SN01

      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. B006L8LN01

      Tighten the 2 bolts and nut in the order shown in the illustration.

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

    5. Engage the 3 wire harness clamps.

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

  12. 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 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 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 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 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 Gasket
      *a Space between Flanges: 8.5 mm (0.335 in.)

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


    1. Engage the wire harness clamp.

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

    3. Connect the heated oxygen sensor connector.

  14. INSTALL CONSOLE BOX ASSEMBLY

    Click here

  15. INSPECT FOR EXHAUST GAS LEAK

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