EXHAUST MANIFOLD INSTALLATION

PROCEDURE

1. INSTALL NO. 1 MANIFOLD CONVERTER INSULATOR

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

      12 N*m

      122 kgf*cm

      9 ft.*lbf

2. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

   1. 

      Install a new gasket to 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.

      35 N*m

      357 kgf*cm

      26 ft.*lbf

3. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

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

      12 N*m

      122 kgf*cm

      9 ft.*lbf

4. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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

      12 N*m

      122 kgf*cm

      9 ft.*lbf

5. INSTALL NO. 2 MANIFOLD STAY

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

      43 N*m

      438 kgf*cm

      32 ft.*lbf

6. INSTALL MANIFOLD STAY

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

      43 N*m

      438 kgf*cm

      32 ft.*lbf

7. INSTALL AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1)

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8. INSTALL RADIATOR HOSE HOSE CLAMP

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9. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

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10. INSTALL FRONT EXHAUST PIPE SUB-ASSEMBLY

    1. 

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

       Minimum length

       41.5 mm (1.63 in.)

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

    2. Using a wire brush, remove any foreign matter from the gasket installation surface.

    3. 

       *1	Gasket
       *2	Wooden Block

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

       Note:

       • Be sure to install the gasket so that it faces the correct direction.

       • Do not reuse the gasket.

       • Do not damage the gasket.

       • When connecting the front exhaust pipe assembly, do not push in the gasket with the front exhaust pipe assembly.

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

    5. Install the front exhaust pipe sub-assembly with the 2 compression springs and 4 bolts.

       43 N*m

       438 kgf*cm

       32 ft.*lbf

    6. Connect the heated oxygen sensor connector.

11. INSTALL GENERATOR ASSEMBLY

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12. INSPECT FOR EXHAUST GAS LEAK

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