EXHAUST MANIFOLD INSTALLATION

INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
1. Text in Illustration
  
  *1 Protrusion
  
  *a Front
  
  Install a new gasket as shown in the illustration.
2. Text in Illustration
  
  *a Front
  
  Install the exhaust manifold sub-assembly LH with 6 new nuts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
  Note
  - Do not damage the stud bolts when installing the exhaust manifold.
  - Be sure to tighten either the nut labeled A or B in the illustration first.
INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
1. Text in Illustration
  
  *1 Protrusion
  
  *a Front
  
  Install a new gasket as shown in the illustration.
2. Text in Illustration
  
  *a Front
  
  Install the exhaust manifold sub-assembly RH with 6 new nuts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
  Note
  - Do not damage the stud bolts when installing the exhaust manifold.
  - Be sure to tighten either the nut labeled A or B in the illustration first.
INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE
1. Install a new O-ring to the No. 2 oil level dipstick guide.
2. Install the No. 2 oil level dipstick guide with the bolt.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
3. Install the oil level dipstick.
INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY
1. Install the No. 1 exhaust pipe support bracket sub-assembly with the 2 bolts.
  
  Torque:
  
  43 N*m { 438 kgf*cm, 32 ft.*lbf }

Text in Illustration
*1	Protrusion
*a	Front

Text in Illustration
*a	Front

Text in Illustration
*1	Protrusion
*a	Front

Text in Illustration
*a	Front

INSTALL FRONT EXHAUST PIPE ASSEMBLY

w/ Protector:

Tech Tips

Only perform this procedure when replacement of the front No. 1 exhaust pipe protector is necessary.
1. Install the front No. 1 exhaust pipe protector and exhaust pipe protector stay with the 2 bolts and 2 nuts.
  
  Torque:
  
  11 N*m { 107 kgf*cm, 8 ft.*lbf }
2. Install the clamp with the bolt.
  
  Torque:
  
  11 N*m { 107 kgf*cm, 8 ft.*lbf }
Using a vernier caliper, measure the free length of the compression springs.

Minimum free length

38.5 mm (1.52 in.)

Tech Tips

If the free length is less than the minimum, replace the compression spring.
Install the 2 new gaskets to the front exhaust pipe assembly.

Minimum free length
38.5 mm (1.52 in.)

Text in Illustration
*1	Front Exhaust Pipe Assembly
*2	Gasket
*3	Wooden Block

Using a plastic-faced hammer and wooden block, tap in a new gasket until its surface is flush with the front exhaust pipe assembly.

Note

Be careful with the installation direction of the gasket.
Do not reuse the gasket.
Do not damage the gasket.
Do not push in the gasket by using the exhaust pipe when connecting it.

Install 2 new gaskets and the front exhaust pipe with 4 new nuts, 8 bolts and 4 compression springs.

Torque:

for exhaust manifold side

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

for tailpipe side

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

CONNECT HEATED OXYGEN SENSOR
1. for Bank 2 Sensor 2:
  1. Before installing the heated oxygen sensor, twist the sensor wires counterclockwise 4 turns.
  2. Text in Illustration
    
    *1 Fulcrum Length
    
    Using SST, connect the heated oxygen sensor to the front exhaust pipe assembly.
    
    SST
    
    09224-00010
    
    Torque:
    
    without SST
    
    44 N*m { 449 kgf*cm, 32 ft.*lbf }
    
    with SST
    
    40 N*m { 408 kgf*cm, 30 ft.*lbf }
    
    Tech Tips
    
    Use a torque wrench with a fulcrum length of 300 mm (11.8 in.). When using a torque wrench with a fulcrum length that is not 300 mm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification Click here.
    
    Make sure SST and the wrench are connected in a straight line.
  3. After installing the sensor, check that the sensor wire is not twisted.
    
    If the sensor wire is twisted, reinstall the sensor.
  4. Connect the grommet of the heated oxygen sensor.
2. for Bank 1 Sensor 2:
  1. Before installing the heated oxygen sensor, twist the sensor wires counterclockwise 4 turns.
  2. Text in Illustration
    
    *1 Fulcrum Length
    
    Using SST, connect the heated oxygen sensor to the front exhaust pipe assembly.
    
    SST
    
    09224-00010
    
    Torque:
    
    without SST
    
    44 N*m { 449 kgf*cm, 32 ft.*lbf }
    
    with SST
    
    40 N*m { 408 kgf*cm, 30 ft.*lbf }
    
    Tech Tips
    
    Use a torque wrench with a fulcrum length of 300 mm (11.8 in.). When using a torque wrench with a fulcrum length that is not 300 mm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification Click here.
    
    Make sure SST and the wrench are connected in a straight line.
  3. After installing the sensor, check that the sensor wire is not twisted.
    
    If the sensor wire is twisted, reinstall the sensor.
  4. Connect the grommet of the heated oxygen sensor.
INSTALL FRONT CENTER FLOOR BRACE
1. Install the front center floor brace with the 2 clips, 6 bolts and 2 nuts.
  
  Torque:
  
  19 N*m { 194 kgf*cm, 14 ft.*lbf }
INSTALL NO. 2 REAR FLOOR BOARD SUB-ASSEMBLY
1. Install the No. 2 rear floor board sub-assembly with the 4 grommets and 7 clips.
INSTALL NO. 1 REAR FLOOR BOARD SUB-ASSEMBLY
1. Install the No. 1 rear floor board sub-assembly with the 4 grommets and 7 clips.
INSTALL NO. 2 ENGINE UNDER COVER
1. Install the No. 2 engine under cover with the 4 screws and 2 grommets.
INSTALL FRONT SUSPENSION MEMBER BRACE
1. Install the front suspension member brace with the clip and 4 bolts.
  
  Torque:
  
  52 N*m { 530 kgf*cm, 38 ft.*lbf }
INSTALL AIR FUEL RATIO SENSOR

Click here
INSPECT FOR EXHAUST GAS LEAK

If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.