EXHAUST MANIFOLD INSTALLATION

  1. INSTALL NO. 1 MANIFOLD CONVERTER INSULATOR

    1. Install the No. 1 manifold converter insulator with the 4 bolts.

      Torque:
      14 N*m  { 138 kgf*cm, 10 ft.*lbf }

  2. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR (except PZEV)

    1. Install the No. 2 exhaust manifold heat insulator with the 2 bolts.

      Torque:
      14 N*m  { 138 kgf*cm, 10 ft.*lbf }

  3. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    1. Install a new exhaust manifold to head gasket onto the cylinder head.

    2. Temporarily install the exhaust manifold converter sub-assembly with the 5 nuts.

    3. Tighten the 5 nuts in the sequence shown in the illustration (except PZEV).

      A011TIME05
      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

    4. Tighten the 5 nuts in the sequence shown in the illustration (for PZEV).

      A011U79E01
      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

  4. INSTALL AIR FUEL RATIO SENSOR

    Click here

  5. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (except PZEV)

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

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

  6. INSTALL EGR INLET EXHAUST MANIFOLD PLATE (for PZEV)

    1. Install the EGR inlet exhaust manifold plate with the bolt.

      Torque:
      14 N*m  { 138 kgf*cm, 10 ft.*lbf }

  7. INSTALL NO. 2 MANIFOLD STAY

    1. Install the No. 2 manifold stay with the bolt and nut.

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

  8. INSTALL MANIFOLD STAY

    1. Install the manifold stay with the bolt and nut.

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

  9. INSTALL FRONT EXHAUST PIPE ASSEMBLY

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

      A011SIYE03
      Minimum 40.5 mm (1.60 in.)

      Tech Tips

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

    2. Fully insert a new gasket to the exhaust manifold converter sub-assembly.

    3. Using a plastic hammer and wooden block, tap in the new gasket until its surface is flush with the exhaust manifold converter sub-assembly.

      A011SNIE16
      Text in Illustration
      *1 Exhaust Manifold Converter Sub-assembly
      *2 Gasket
      *3 Wooden Block

      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 pipe when connecting it.

    4. Install a new gasket to the front exhaust pipe assembly.

    5. Connect the front exhaust pipe assembly to the exhaust pipe support.

    6. Install the front exhaust pipe assembly with the 2 compression springs, 2 bolts and 2 nuts.

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

    7. Connect the heated oxygen sensor connector.

  10. INSTALL ENGINE UNDER COVER RH

  11. INSTALL ENGINE UNDER COVER LH

  12. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH

  13. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH

  14. INSPECT FOR EXHAUST GAS LEAK