EXHAUST MANIFOLD INSTALLATION

PROCEDURE

  1. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (TWC: Front Catalyst)

    1. Install a new exhaust manifold to head gasket and a new inlet EGR gasket.

    2. A235361E03

      Install the exhaust manifold converter sub-assembly (TWC: Front Catalyst) with 7 new nuts in the order shown in the illustration.

      32 N*m

      326 kgf*cm

      24 ft.*lbf

  2. INSTALL MANIFOLD STAY

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

      21 N*m

      214 kgf*cm

      15 ft.*lbf

  3. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

    1. Install the No. 2 exhaust manifold heat insulator to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) with the 2 bolts.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

  4. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    1. Install the No. 1 exhaust manifold heat insulator to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) with the 2 nuts and bolt.

      7.5 N*m

      76 kgf*cm

      66 in.*lbf

  5. INSTALL OIL LEVEL DIPSTICK GUIDE SUB-ASSEMBLY

    1. Install a new O-ring to the oil level dipstick guide sub-assembly.

    2. Install the oil level dipstick guide sub-assembly with the bolt.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

      Tip:

      Apply engine oil to the O-ring and install the oil level dipstick guide sub-assembly into the oil pan.

    3. Install the oil level dipstick sub-assembly.

  6. INSTALL AIR FUEL RATIO SENSOR

    Click here

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

    1. A128853

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

      Minimum

      41.5 mm (1.63 in.)

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

    2. A181728C47

      *1

      Exhaust Manifold Converter Sub-assembly (TWC: Front Catalyst)

      *2

      Gasket

      *a

      Wooden Block

      Using a plastic hammer and wooden block, tap in the new gasket until each surface is flush with the exhaust manifold converter sub-assembly (TWC: Front Catalyst).

      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 pipes when connecting it.

    3. Install a new gasket to the front exhaust pipe assembly (TWC: Rear Catalyst).

    4. A247546C07

      *1

      Exhaust Manifold Converter Sub-assembly (TWC: Front Catalyst)

      *2

      Front Exhaust Pipe Assembly (TWC: Rear Catalyst)

      *3

      Gasket

      *a

      Space between flanges: 8.5 mm (0.335 in.)

      Install the front exhaust pipe assembly (TWC: Rear Catalyst) with the 4 bolts and 2 compression springs.

      43 N*m

      438 kgf*cm

      32 ft.*lbf

      Tip:

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

    5. Connect the heated oxygen sensor connector and clamp.

  8. INSPECT FOR EXHAUST GAS LEAK