PROCEDURE
INSTALL STUD BOLT
Tech Tips
If a stud bolt is deformed or the threads are damaged, replace it.
Using an E8 "TORX" socket wrench, install the stud bolt to the exhaust manifold converter sub-assembly (TWC: Front Catalyst).
INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
Install the No. 2 exhaust manifold heat insulator to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) with the 2 bolts.
INSTALL NO. 1 MANIFOLD CONVERTER INSULATOR
Install the No. 1 manifold converter insulator to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) with the 3 bolts.
INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (TWC: Front Catalyst)
Install a new exhaust manifold gasket to the cylinder head sub-assembly.
Temporarily install the exhaust manifold converter sub-assembly (TWC: Front Catalyst) to the cylinder head sub-assembly with the 5 nuts.
Install 2 new EGR cooler gaskets to the EGR pipe connector.
Temporarily install the EGR pipe connector to the exhaust manifold converter sub-assembly (TWC: Front Catalyst), EGR cooler assembly and cylinder block sub-assembly with the 4 bolts and nut.
Tighten the 5 nuts in the order shown in the illustration.
*a | Bolt (A) |
*b | Bolt (B) |
Bolt | |
Nut |
Tighten the 4 bolts and nut.
INSTALL NO. 2 MANIFOLD STAY
Install the No. 2 manifold stay to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and stiffening crankcase assembly with the bolt and nut.
INSTALL MANIFOLD STAY
Install the manifold stay to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and stiffening crankcase assembly with the bolt and nut.
INSTALL AIR FUEL RATIO SENSOR
INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
Install the No. 1 exhaust manifold heat insulator to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) with the 4 bolts.
INSTALL INLET AIR CLEANER ASSEMBLY
INSTALL COOL AIR INTAKE DUCT SEAL
INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)
Using a vernier caliper, measure the free length of the 2 compression springs.
Minimum Free Length | 40.5 mm (1.59 in.) |
If the free length is less than the minimum, replace the compression spring.
Temporarily install a new exhaust pipe gasket to the exhaust manifold converter sub-assembly (TWC: Front Catalyst).
*1 | Exhaust Manifold Converter Sub-assembly (TWC: Front Catalyst) |
*2 | Exhaust Pipe Gasket |
*a | Wooden Block |
Using a plastic hammer and wooden block, tap in the exhaust pipe gasket until its surface is flush with the exhaust manifold converter sub-assembly (TWC: Front Catalyst).
Note
Be careful with the installation direction of the exhaust pipe gasket.
Do not reuse the exhaust pipe gasket.
Do not damage the exhaust pipe gasket.
Do not push in the exhaust pipe gasket by using the exhaust pipe when connecting it.
Install a new exhaust pipe gasket to the front exhaust pipe assembly (TWC: Rear Catalyst).
Connect the front exhaust pipe assembly (TWC: Rear Catalyst) to the exhaust pipe support.
Install the front exhaust pipe assembly (TWC: Rear Catalyst) to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and center exhaust pipe assembly with the 2 compression springs, 2 bolts and 2 nuts.
Tech Tips
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) is consistent front-to-rear and left-to-right.
*1 | Exhaust Manifold Converter Sub-assembly (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.) |
Connect the heated oxygen sensor connector.
INSPECT FOR EXHAUST GAS LEAK
INSTALL ENGINE UNDER COVER LH
INSTALL FRONT WHEEL OPENING EXTENSION PAD LH
INSTALL ENGINE UNDER COVER RH
INSTALL FRONT WHEEL OPENING EXTENSION PAD RH