EXHAUST MANIFOLD INSTALLATION

PROCEDURE


  1. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the No. 2 exhaust manifold heat insulator to the exhaust manifold (TWC: Front Catalyst) with the 4 bolts.

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

  2. INSTALL EXHAUST MANIFOLD (TWC: Front Catalyst)


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

    2. Temporarily install the exhaust manifold (TWC: Front Catalyst) to the cylinder head sub-assembly with 7 new nuts.

    3. Temporarily install the manifold stay to the exhaust manifold (TWC: Front Catalyst) and cylinder block sub-assembly with the 3 bolts.

    4. A003MBON01

      Using a 12 mm deep socket wrench, tighten the 7 nuts in the order shown in the illustration.

      Torque:
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }
    5. A003NKTN01

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

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

    6. for LHD:


      1. Engage the clamp.

      2. A003O90C01
        B006IFV Connect
        B006IV0 Lock

        Connect the brake booster pump assembly connector and lock the lock lever as shown in the illustration.

        Note


        • Make sure that the connector is locked securely.

        • Make sure that the connector can be connected smoothly. Do not allow water, oil or dirt to enter.

    7. Connect the engine coolant temperature sensor connector.

    8. Connect the water pipe and hose sub-assembly A to the bracket with the nut.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  3. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the No. 1 exhaust manifold heat insulator to the exhaust manifold (TWC: Front Catalyst) with the 6 bolts.

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

  4. INSTALL WIRING HARNESS CLAMP BRACKET


    1. Install the wiring harness clamp bracket to the cylinder head sub-assembly with the bolt and engage the clamp.

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

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


    1. A003P7E

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

      Minimum Free Length (Front) 41.5 mm (1.63 in.)
      Minimum Free Length (Rear) 38.5 mm (1.52 in.)

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

    2. Temporarily install 2 new exhaust pipe gaskets to the exhaust manifold (TWC: Front Catalyst) and front exhaust pipe assembly (TWC: Rear Catalyst).

    3. A003OLAC59
      *1 Exhaust Manifold (TWC: Front Catalyst) or Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
      *2 Exhaust Pipe Gasket
      *a Wooden Block

      Using a plastic hammer and wooden block, tap in each exhaust pipe gasket until its surface is flush with the exhaust manifold (TWC: Front Catalyst) and front exhaust pipe assembly (TWC: Rear Catalyst).

      Note


      • Be sure to install the exhaust pipe gasket in the correct direction.

      • Do not reuse the exhaust pipe gaskets.

      • Do not damage the exhaust pipe gaskets.

      • Do not push in the exhaust pipe gaskets by using the exhaust pipes when connecting them.

    4. Connect the front exhaust pipe assembly (TWC: Rear Catalyst) to the 2 exhaust pipe supports.

    5. Install the front exhaust pipe assembly (TWC: Rear Catalyst) to the exhaust manifold (TWC: Front Catalyst) with the 2 compression springs and 2 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 (TWC: Front Catalyst) and front exhaust pipe assembly (TWC: Rear Catalyst) is consistent front-to-rear and left-to-right.

      A003NALC18
      *1 Exhaust Manifold (TWC: Front Catalyst)
      *2 Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
      *3 Exhaust Pipe Gasket
      *a Space between Flanges: 8.5 mm (0.335 in.)

    6. Install the front exhaust pipe assembly (TWC: Rear Catalyst) to the tail exhaust pipe assembly with the 2 compression springs and 2 bolts.

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

      Tech Tips

      After installation, check that the space between the flanges of the front exhaust pipe assembly (TWC: Rear Catalyst) and tail exhaust pipe assembly is consistent front-to-rear and left-to-right.

      A003NALC37
      *1 Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
      *2 Tail Exhaust Pipe Assembly
      *3 Exhaust Pipe Gasket
      *a Space between Flanges: 6.5 mm (0.256 in.)

    7. Engage the wire harness clamp.

    8. Connect the heated oxygen sensor connector.

    9. Connect the outlet heater water hose B and outlet heater water hose C to the No. 2 outlet water pipe and inlet water pipe and slide the 2 clips to secure them.

      Note

      When installing the outlet heater water hose B and outlet heater water hose C, ensure that the exhaust heat recirculation system is filled with coolant. Otherwise, the engine water pump assembly may be damaged.

  6. INSTALL AIR FUEL RATIO SENSOR

    Click here

  7. ADD ENGINE COOLANT

    Click here

  8. INSPECT FOR COOLANT LEAK

    Click here

  9. INSPECT FOR EXHAUST GAS LEAK

    Click here

  10. INSTALL FRONT CENTER FLOOR BRACE


    1. Install the 3 front center floor braces to the vehicle body with the 12 bolts.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

  11. INSTALL FRONT FLOOR COVER LH


    1. Engage the 5 clamps to install the front floor cover LH to the vehicle body with the 2 bolts and 3 clips.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  12. INSTALL FRONT FLOOR COVER RH

    Tech Tips

    Perform the same procedure as for the front floor cover LH.

  13. INSTALL NO. 2 ENGINE UNDER COVER

    Click here

  14. INSTALL REAR ENGINE UNDER COVER LH

    Click here

  15. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

    Click here