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 with the 4 bolts.

      Torque:

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

2. INSTALL EXHAUST MANIFOLD

   
   

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

   2. 

      Temporarily install the exhaust manifold with 5 new nuts.

   3. 

      Temporarily install the manifold stay with the 3 bolts.

   4. Tighten the 5 exhaust manifold nuts.

      Torque:

      26 N*m  { 265 kgf*cm, 19 ft.*lbf }

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

      Torque:

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

3. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

   
   

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

      Torque:

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

   2. Install the wire harness clamp bracket to the cylinder head sub-assembly with the bolt.

      Torque:

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

   3. Engage the 3 clamps.

4. INSTALL AIR FUEL RATIO SENSOR

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

   
   

   1. 

      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 and front exhaust pipe assembly (TWC: Front and Rear Catalyst).

   3. 

      *1	Exhaust Manifold or Front Exhaust Pipe Assembly (TWC: Front and 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 and front exhaust pipe assembly (TWC: Front and 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: Front and Rear Catalyst) to the 2 exhaust pipe supports.

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

      

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

   6. Install the front exhaust pipe assembly (TWC: Front and 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: Front and Rear Catalyst) and tail exhaust pipe assembly is consistent front-to-rear and left-to-right.

      

      *1	Front Exhaust Pipe Assembly (TWC: Front and 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.

6. INSTALL FRONT FLOOR CENTER BRACE

   
   

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

      Torque:

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

7. INSPECT FOR EXHAUST GAS LEAK

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8. INSTALL NO. 1 ENGINE UNDER COVER

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