INSTALLATION

PROCEDURE

1. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

(a) for Type A:

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

Torque:

11 N·m {112 kgf·cm, 8 ft·lbf}

(b) for Type B:

Install the No. 2 exhaust manifold heat insulator to the exhaust manifold with the 6 bolts.

Torque:

11 N·m {112 kgf·cm, 8 ft·lbf}

2. INSTALL EXHAUST MANIFOLD

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

(b) Temporarily install the exhaust manifold, No. 1 exhaust manifold heat insulator and No. 1 upper front floor heat insulator.

HINT:

At this time, do not install the parts with bolts or nuts.

(c) Using a 12 mm deep socket wrench, temporarily install the exhaust manifold to the cylinder head sub-assembly with 7 new nuts.

(d) Using the 12 mm deep socket wrench, tighten the 7 nuts in the order shown in the illustration.

Torque:

26 N·m {265 kgf·cm, 19 ft·lbf}

3. INSTALL MANIFOLD STAY

(a) Temporarily install the manifold stay to the exhaust manifold and cylinder block sub-assembly with the bolt and nut.

(b) Tighten the bolt and nut in the order shown in the illustration.

Torque:

43 N·m {438 kgf·cm, 32 ft·lbf}

4. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

(a) for Type A: Using a 10 mm union nut wrench, install the No. 1 exhaust manifold heat insulator to the exhaust manifold with the 3 bolts. Torque: Specified tightening torque : 10 N·m {102 kgf·cm, 7 ft·lbf} HINT: Calculate the torque wrench reading when changing the fulcrum length of the torque wrench. Click here When using a 10 mm union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)): 8.8 N*m (90 kgf*cm, 78 in.*lbf)

*a Torque Wrench Fulcrum Length

(b) for Type B: Using a 10 mm union nut wrench, install the No. 1 exhaust manifold heat insulator to the exhaust manifold with the 5 bolts. Torque: Specified tightening torque : 10 N·m {102 kgf·cm, 7 ft·lbf} HINT: Calculate the torque wrench reading when changing the fulcrum length of the torque wrench. Click here When using a 10 mm union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)): 8.8 N*m (90 kgf*cm, 78 in.*lbf)

*a Torque Wrench Fulcrum Length

5. INSTALL NO. 1 UPPER FRONT FLOOR HEAT INSULATOR

(a) Install the No. 1 upper front floor heat insulator to the vehicle body with the 2 nuts.

Torque:

4.9 N·m {50 kgf·cm, 43 in·lbf}

6. INSTALL WIRE HARNESS CLAMP BRACKET

(a) Install the wire harness clamp bracket with the bolt.

Torque:

13 N·m {133 kgf·cm, 10 ft·lbf}

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

Click here

8. INSTALL FRONT EXHAUST PIPE ASSEMBLY

(a) Install 2 new gaskets to the front exhaust pipe assembly.

(b) Connect the front exhaust pipe assembly to the 2 exhaust pipe supports.

(c) Install the front exhaust pipe assembly to the exhaust manifold and tail exhaust pipe assembly with 2 new bolts and 2 new nuts.

Torque:

43 N·m {438 kgf·cm, 32 ft·lbf}

(d) Connect the air fuel ratio sensor connector.

*a Tie Band *b Wire Harness Clamp

(e) Attach the 2 wire harness clamps so that the tie band is positioned as shown in the illustration.

9. INSPECT FOR EXHAUST GAS LEAK

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10. INSTALL ENGINE UNDER COVER HEAT INSULATOR

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11. INSTALL NO. 2 ENGINE UNDER COVER ASSEMBLY

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