EXHAUST MANIFOLD INSTALLATION

PROCEDURE

1. INSTALL EXHAUST MANIFOLD (TWC: Catalyst)

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

   2. Temporarily install the exhaust manifold (TWC: Catalyst) to the cylinder head sub-assembly with the 2 bolts and 4 nuts.

   3. 

      	Bolt
      	Nut (A)
      	Nut (B)

      Tighten the 2 bolts and 4 nuts in the order shown in the illustration.

      Bolt and Nut (A)

      29 N*m

      296 kgf*cm

      21 ft.*lbf

      Nut B

      28 N*m

      286 kgf*cm

      21 ft.*lbf

2. INSTALL MANIFOLD STAY

   1. Temporarily install the manifold stay to the exhaust manifold (TWC: Catalyst) and cylinder block sub-assembly with the bolt and nut.

   2. 

      	Bolt
      	Nut

      Tighten the bolt and nut in the order shown in the illustration.

      24 N*m

      245 kgf*cm

      18 ft.*lbf

3. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

   1. Install the No. 1 exhaust manifold heat insulator to the exhaust manifold (TWC: Catalyst) with the 3 bolts.

      8.5 N*m

      87 kgf*cm

      75 in.*lbf

4. INSTALL FRONT EXHAUST PIPE ASSEMBLY

   1. 

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

      Minimum

      40.5 mm (1.59 in.)

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

   2. Temporarily install a new gasket to the exhaust manifold (TWC: Catalyst).

   3. 

      *1	Exhaust Manifold (TWC: Catalyst)
      *2	Gasket
      *a	Wooden Block

      Using a plastic hammer and wooden block, tap in the gasket until its surface is flush with the exhaust manifold (TWC: 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 pipe when connecting it.

   4. w/o Catalytic Converter:

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

   5. w/ Catalytic Converter:

      1. Connect the front exhaust pipe assembly (TWC: Rear Catalyst) to the exhaust pipe support.

   6. w/o Catalytic Converter:

      1. 

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

         Install the front exhaust pipe assembly to the exhaust manifold (TWC: Catalyst) with the 2 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 (TWC: Catalyst) and front exhaust pipe assembly is consistent front-to-rear and left-to-right.

   7. w/ Catalytic Converter:

      1. 

         *1	Exhaust Manifold (TWC: 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) to the exhaust manifold (TWC: Catalyst) with the 2 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 (TWC: Catalyst) and front exhaust pipe assembly (TWC: Rear Catalyst) is consistent front-to-rear and left-to-right.

5. INSTALL HEATED OXYGEN SENSOR (Sensor 1)

   Click here

6. INSPECT FOR EXHAUST GAS LEAK

   Click here

7. INSTALL FRONT BUMPER ASSEMBLY

   Click here