EXHAUST MANIFOLD INSTALLATION

PROCEDURE


  1. INSTALL STUD BOLT

    Tech Tips

    If a stud bolt is deformed or its threads are damaged, replace it.


    1. B005M8S

      Using an E8 "TORX" socket wrench, install the 2 stud bolts to the exhaust manifold (TWC: Front Catalyst).

      Torque:
      19.5 N*m  { 199 kgf*cm, 14 ft.*lbf }
    2. B005PN8

      Using an E8 "TORX" socket wrench, install the 2 stud bolts to the exhaust manifold assembly LH (TWC: Front Catalyst).

      Torque:
      19.5 N*m  { 199 kgf*cm, 14 ft.*lbf }

  2. INSTALL EXHAUST MANIFOLD TO HEAD GASKET (for Bank 2)


    1. Install a new exhaust manifold to head gasket (for Bank 2) to the cylinder head sub-assembly.

  3. INSTALL EXHAUST MANIFOLD ASSEMBLY LH (TWC: Front Catalyst)


    1. Temporarily install the exhaust manifold assembly LH (TWC: Front Catalyst) with the 4 nuts.

    2. Temporarily install the No. 2 manifold stay to the exhaust manifold assembly LH (TWC: Front Catalyst) and cylinder block sub-assembly with the bolt and nut.

    3. B007X29N01

      Using a 12 mm deep socket wrench, tighten the 4 nuts in the order shown in the illustration.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    4. B007WOOC05
      B007WXX Bolt
      B00803L Nut

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

      Torque:
      34 N*m  { 347 kgf*cm, 25 ft.*lbf }

    5. Connect the No. 1 radiator hose to the radiator assembly and slide the clip to secure it.

    6. Connect the 2 No. 2 cooling fan motor connectors.

  4. INSTALL AIR FUEL RATIO SENSOR (for Bank 2)

    Click here

  5. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. B007XDXN01

      Install the No. 2 exhaust manifold heat insulator to the exhaust manifold assembly LH (TWC: Front Catalyst) with the 3 bolts in the order shown in the illustration.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

    2. Engage the wire harness clamp.

    3. Connect the air fuel ratio sensor connector.

  6. INSTALL V-BANK COVER SUB-ASSEMBLY

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  7. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  8. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  9. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET (for Lower Side)

    Click here

  10. INSTALL EXHAUST MANIFOLD TO HEAD GASKET (for Bank 1)


    1. Install a new exhaust manifold to head gasket (for Bank 1) to the cylinder head sub-assembly RH.

  11. INSTALL EXHAUST MANIFOLD (TWC: Front Catalyst)


    1. Temporarily install the exhaust manifold (TWC: Front Catalyst) with the 4 nuts.

    2. Temporarily install the manifold stay to the exhaust manifold (TWC: Front Catalyst) and rear engine mounting bracket with the bolt and nut.

    3. B007ZZXN01

      Using a 12 mm deep socket wrench, tighten the 4 nuts in the order shown in the illustration.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    4. B007YNYC02
      B007WXX Bolt
      B00803L Nut

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

      Torque:
      34 N*m  { 347 kgf*cm, 25 ft.*lbf }

  12. INSTALL FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY


    1. B007Y2G

      Using a vernier caliper, measure the free length of the 2 compression springs.

      Standard Length 43.0 mm (1.69 in.)
      Minimum Free Length 41.5 mm (1.63 in.)

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

    2. Temporarily install a new exhaust pipe gasket to the front No. 3 exhaust pipe sub-assembly (center exhaust pipe assembly (TWC: Rear Catalyst) side).

    3. B007ZWBC68
      *1 Front No. 3 Exhaust Pipe Sub-assembly
      *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 front No. 3 exhaust pipe sub-assembly.

      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 pipes when connecting them.

    4. Install 2 new exhaust pipe gaskets to the front No. 3 exhaust pipe sub-assembly.

    5. Temporarily install the front No. 3 exhaust pipe sub-assembly with the 4 bolts, 2 nuts and 2 compression springs.

    6. Tighten the 2 bolts and 2 nuts.

      Torque:
      55 N*m  { 561 kgf*cm, 41 ft.*lbf }

    7. Tighten the 2 bolts and 2 compression springs.

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

      Tech Tips

      After installation, check that the space between the flanges of the center exhaust pipe assembly (TWC: Rear Catalyst) and front No. 3 exhaust pipe sub-assembly is consistent front-to-rear and left-to-right.

      B007ZK0C27
      *1 Center Exhaust Pipe Assembly (TWC: Rear Catalyst)
      *2 Front No. 3 Exhaust Pipe Sub-assembly
      *3 Exhaust Pipe Gasket
      *a Space between Flanges: 8.5 mm (0.335 in.)

    8. Connect the heated oxygen sensor (for Bank 1) connector.

    9. Engage the 4 wire harness clamps.

  13. INSTALL FRONT FLOOR COVER LH


    1. B007XBMC02
      B007WXX Bolt
      B00803L Screw

      Install the front floor cover LH with the 2 clips (B).

    2. Install the clip (A), 2 screws and 4 bolts to the front floor cover LH.

  14. INSTALL AIR FUEL RATIO SENSOR (for Bank 1)

    Click here

  15. INSTALL NO. 2 ENGINE UNDER COVER

    Click here

  16. ADD ENGINE COOLANT

    Click here

  17. INSPECT FOR COOLANT LEAK

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  18. INSPECT FOR EXHAUST GAS LEAK

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