EXHAUST MANIFOLD INSTALLATION

PROCEDURE


  1. INSTALL EXHAUST MANIFOLD


    1. B0026ESC01
      *A w/ Secondary Air Injection System
      *B w/o Secondary Air Injection System

      Install a new gasket.

    2. B00271QN01

      w/o Secondary Air Injection System:

      Install the exhaust manifold with 6 new nuts, and tighten the nuts in the order shown in the illustration.

      Torque:
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }
    3. B0026XRN01

      w/ Secondary Air Injection System:

      Install the exhaust manifold with 8 new nuts, and tighten the nuts in the order shown in the illustration.

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

  2. INSTALL MANIFOLD STAY


    1. B0025TDN01

      for Manual Transmission:

      Install the manifold stay with the 3 bolts.

      Torque:
      for bolt A
      71.5 N*m  { 729 kgf*cm, 53 ft.*lbf }
      for bolt B
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }
      for bolt C
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

    2. for Automatic Transmission:

      Install the manifold stay with the 3 bolts.

      Torque:
      for bolt A
      71 N*m  { 724 kgf*cm, 52 ft.*lbf }
      for bolt B
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }
      for bolt C
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  3. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (w/o Secondary Air Injection System)


    1. Install the No. 1 exhaust manifold heat insulator with the 5 bolts.

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

  4. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. A01SC22

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

      Minimum free length
      40 mm (1.57 in.)

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

    2. B006913C38
      *1 Gasket
      *a Wooden Block

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

      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.

    3. Install the front exhaust pipe assembly to the No. 1 exhaust pipe support.

    4. Connect the front exhaust pipe assembly to the exhaust manifold with the 2 compression springs and 2 bolts. Alternately tighten the bolts in several passes.

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

    5. Install a new gasket and connect the front exhaust pipe assembly to the tail exhaust pipe assembly with the 2 bolts and 2 new nuts.

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

    6. for 2WD:

      Connect the heated oxygen sensor connector and attach the 4 wire harness clamps.

    7. for 4WD:

      Connect the heated oxygen sensor connector and attach the wire harness clamp.

    8. Connect the air fuel ratio sensor connector and attach the 3 wire harness clamps.

  5. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (w/o Secondary Air Injection System)

    Click here

  6. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY (w/o Secondary Air Injection System)

    Click here

  7. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH NO. 1 AIR CLEANER HOSE (w/o Secondary Air Injection System)

    Click here

  8. INSTALL AIR SWITCHING VALVE ASSEMBLY (w/ Secondary Air Injection System)

    Click here

  9. INSPECT FOR EXHAUST GAS LEAK

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  10. INSTALL FRONT FENDER SEAL RH

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