EXHAUST MANIFOLD INSTALLATION

PROCEDURE

1. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

   

   1. Install the No. 2 exhaust manifold heat insulator with the 3 bolts.

      12 N*m

      122 kgf*cm

      9 ft.*lbf

2. INSTALL EXHAUST MANIFOLD

   1. Install a new exhaust manifold gasket.

   2. for Nut Type A:

      1. 

         Install the exhaust manifold with the 5 nuts.

         21 N*m

         214 kgf*cm

         15 ft.*lbf

         Table 1. Text in Illustration

         *A	for Nut Type A
         *B	for Nut Type B

   3. for Nut Type B:

      1. Install the exhaust manifold with 5 new nuts.

         26 N*m

         265 kgf*cm

         19 ft.*lbf

3. INSTALL MANIFOLD STAY

   1. 

      Temporarily install the manifold stay with the 3 bolts.

   2. While pushing the manifold stay toward the exhaust manifold, tighten the 2 bolts labeled 1.

      43 N*m

      438 kgf*cm

      32 ft.*lbf

   3. Tighten the bolt labeled 2.

      43 N*m

      438 kgf*cm

      32 ft.*lbf

4. INSTALL DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY

   

   1. Install the drive shaft heat insulator sub-assembly with the 2 nuts.

      18 N*m

      179 kgf*cm

      13 ft.*lbf

5. INSTALL FRONT EXHAUST PIPE ASSEMBLY

   1. 

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

      Minimum Free Length

      Item	Specified Condition
      Front side compression spring	43 mm (1.69 in.)
      Rear side compression spring	40 mm (1.57 in.)

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

   2. 

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

      Table 2. Text in Illustration

      *1	Exhaust Pipe Gasket
      *a	Wooden Block

      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 exhaust pipe, do not push in the gasket with the exhaust pipe.

   3. 

      Install the 3 exhaust pipe supports, and then install the front exhaust pipe assembly with the 2 compression springs and 2 bolts.

      43 N*m

      438 kgf*cm

      32 ft.*lbf

   4. 

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

      Table 3. Text in Illustration

      *1	Exhaust Pipe Gasket
      *a	Wooden Block

      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 exhaust pipe, do not push in the gasket with the exhaust pipe.

   5. 

      Connect the front exhaust pipe assembly to the tailpipe assembly with the 2 compression springs and 2 bolts.

      43 N*m

      438 kgf*cm

      32 ft.*lbf

   6. Connect the heated oxygen sensor connector.

   7. Attach the clamp to connect the heated oxygen sensor wire harness.

6. INSTALL FRONT FLOOR CENTER BRACE

   

   1. Install the front floor center brace with the 4 bolts.

      51 N*m

      520 kgf*cm

      38 ft.*lbf

7. INSTALL NO. 2 ENGINE UNDER COVER

   1. 

      Install the No. 2 engine under cover with the 4 clips.

8. 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

9. INSTALL WIRE HARNESS CLAMP BRACKET

   1. 

      Install the wire harness clamp bracket with the bolt.

      60 N*m

      612 kgf*cm

      44 ft.*lbf

10. INSTALL AIR FUEL RATIO SENSOR

    Click here

11. INSTALL OUTER COWL TOP PANEL

    1. 

       Install the outer cowl top panel with the 9 bolts.

       8.8 N*m

       90 kgf*cm

       78 in.*lbf

       Table 4. Text in Illustration

       *A	for LHD
       *B	for RHD

    2. Connect the connector clamp.

12. INSTALL WINDSHIELD WIPER MOTOR AND LINK

    1. Install the windshield wiper motor and link (Click here).

13. INSTALL NO. 2 CYLINDER HEAD COVER

    Click here

14. INSPECT FOR EXHAUST GAS LEAK

    Click here