INSTALLATION

PROCEDURE

1. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

(a) Install the No. 2 exhaust manifold heat insulator to the exhaust manifold (TWC: Front Catalyst) with the 4 bolts.

Torque:

12 N·m {122 kgf·cm, 9 ft·lbf}

2. INSTALL EXHAUST MANIFOLD (TWC: Front Catalyst)

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

(b) Temporarily install the exhaust manifold (TWC: Front Catalyst) to the cylinder head sub-assembly with 7 new nuts.

(c) Temporarily install the manifold stay to the exhaust manifold (TWC: Front Catalyst) and cylinder block sub-assembly with the 3 bolts.

(d) Using a 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}

(e) Tighten the 3 bolts in the order shown in the illustration. Torque: 43 N·m {438 kgf·cm, 32 ft·lbf}

3. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

(a) Install the No. 1 exhaust manifold heat insulator to the exhaust manifold (TWC: Front Catalyst) with the 6 bolts.

Torque:

12 N·m {122 kgf·cm, 9 ft·lbf}

4. INSTALL WIRING HARNESS CLAMP BRACKET

(a) Install the wiring harness clamp bracket to the engine assembly with the bolt and engage the clamp.

Torque:

39 N·m {398 kgf·cm, 29 ft·lbf}

5. CONNECT FLOOR SHIFT TRANSMISSION CONTROL SELECT CABLE

(a) Connect the floor shift transmission control select cable to the engine assembly with the bolt.

Torque:

12 N·m {122 kgf·cm, 9 ft·lbf}

6. INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR

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7. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)

(a) Using a vernier caliper, measure the free length of the compression springs. Minimum Free Length (Front) 41.5 mm (1.63 in.) Minimum Free Length (Rear) 38.5 mm (1.52 in.) If the free length is less than the minimum, replace the compression spring.

(b) Temporarily install 2 new gaskets to the exhaust manifold (TWC: Front Catalyst) and front exhaust pipe assembly (TWC: Rear Catalyst).

(c) Using a plastic hammer and wooden block, tap in each gasket until its surface is flush with the exhaust manifold (TWC: Front Catalyst) and front exhaust pipe assembly (TWC: Rear Catalyst). NOTICE: Be sure to install the gasket in the correct direction. Do not reuse the gaskets. Do not damage the gaskets. Do not push in the gaskets by using the exhaust pipes when connecting them.

*1 Exhaust Manifold (TWC: Front Catalyst) or Front Exhaust Pipe Assembly (TWC: Rear Catalyst) *2 Gasket *a Wooden Block

(d) Connect the front exhaust pipe assembly (TWC: Rear Catalyst) to the 2 exhaust pipe supports.

(e) Install the front exhaust pipe assembly (TWC: Rear Catalyst) to the exhaust manifold (TWC: Front Catalyst) with the 2 compression springs and 2 bolts.

Torque:

43 N·m {438 kgf·cm, 32 ft·lbf}

HINT:

After installation, check that the space between the flanges of the exhaust manifold (TWC: Front Catalyst) and front exhaust pipe assembly (TWC: Rear Catalyst) is consistent front-to-rear and left-to-right.

(f) Install the front exhaust pipe assembly (TWC: Rear Catalyst) to the tail exhaust pipe assembly with the 2 compression springs and 2 bolts.

Torque:

43 N·m {438 kgf·cm, 32 ft·lbf}

HINT:

After installation, check that the space between the flanges of the front exhaust pipe assembly (TWC: Rear Catalyst) and tail exhaust pipe assembly is consistent front-to-rear and left-to-right.

(g) Engage the wire harness clamp.

(h) Connect the heated oxygen sensor connector.

8. INSTALL FRONT FLOOR CENTER BRACE

(a) Install the 3 front floor center braces to the vehicle body with the 12 bolts.

Torque:

29 N·m {296 kgf·cm, 21 ft·lbf}

9. INSTALL FRONT FLOOR COVER LH

(a) Engage the 6 clamps to install the front floor cover LH to the vehicle body with the 2 bolts and 3 clips.

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

10. INSTALL FRONT FLOOR COVER RH

HINT:

Perform the same procedure as for the front floor cover LH.

11. INSTALL AIR FUEL RATIO SENSOR

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12. INSPECT FOR EXHAUST GAS LEAK

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13. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

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