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 3 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

2. INSTALL EXHAUST MANIFOLD (TWC: Front Catalyst)

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

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

(c) 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 (TWC: Front Catalyst) 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) Install the No. 1 exhaust manifold heat insulator to the exhaust manifold (TWC: Front Catalyst) with the 3 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

5. INSTALL AIR FUEL RATIO SENSOR

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6. INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR

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 air fuel ratio sensor connector.

8. INSTALL FRONT FLOOR CENTER BRACE

(a) for Hatchback:

(1) 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}

(b) except Hatchback:

(1) Install the 2 front floor center braces to the vehicle body with the 8 bolts.

Torque:

29 N·m {296 kgf·cm, 21 ft·lbf}

9. INSTALL FRONT FLOOR COVER LH

(a) for Hatchback:

(1) 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}

(b) except Hatchback:

(1) w/ Cover:

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. INSPECT FOR EXHAUST GAS LEAK

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12. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

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