Exhaust Manifold Converter Installation

Install the No. 1 manifold converter insulator with the 3 bolts and nut.

Torque:

25 N*m{255 kgf*cm, 18 ft.*lbf}

Temporarily install the No. 2 vacuum pipe with the bolt and nut.

Tighten the bolt and nut.

Torque:

18 N*m{184 kgf*cm, 13 ft.*lbf}

Using SST, tighten the nut of the No. 2 vacuum pipe.

SST

09023-38401

Torque:

30 N*m{306 kgf*cm, 22 ft.*lbf}

HINT:

Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

Temporarily install the No. 1 vacuum pipe with the nut.

Tighten the nut.

Torque:

18 N*m{184 kgf*cm, 13 ft.*lbf}

Using SST, tighten the nut of the No. 1 vacuum pipe.

SST

09023-38401

Torque:

30 N*m{306 kgf*cm, 22 ft.*lbf}

HINT:

Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

Temporarily install the exhaust gas temperature sensor (lower) with the 2 nuts.

Tighten the 2 nuts.

Torque:

6.4 N*m{65 kgf*cm, 57 in.*lbf}

Using SST, tighten the nut of the exhaust gas temperature sensor (lower).

SST

09023-38401

Torque:

30 N*m{306 kgf*cm, 22 ft.*lbf}

Temporarily install the exhaust gas temperature sensor (upper).

Tighten the 3 nuts.

Torque:

6.4 N*m{65 kgf*cm, 57 in.*lbf}

Using SST, tighten the nut of the exhaust gas temperature sensor (upper).

SST

09023-38401

Torque:

30 N*m{306 kgf*cm, 22 ft.*lbf}

HINT:

Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

Temporarily install the No. 1 manifold stay.

Temporarily install a new turbine outlet elbow gasket and exhaust manifold converter with the 3 nuts.

Temporarily install the 2 bolts and nut.

Tighten the 3 nuts (Pushing the manifold converter against the No. 1 manifold stay).

Torque:

25 N*m{255 kgf*cm, 18 ft.*lbf}

Tighten the 2 bolts and nut.

Torque:

56 N*m{571 kgf*cm, 41 ft.*lbf}

Temporarily install the No. 2 exhaust manifold stay with the 2 bolts and nut.

Tighten the 2 bolts (Pushing the No. 2 exhaust manifold stay against the manual transmission).

Torque:

56 N*m{571 kgf*cm, 41 ft.*lbf}

Tighten the nut.

Torque:

56 N*m{571 kgf*cm, 41 ft.*lbf}

Using pliers, slide the clip to install the No. 1 and No. 2 vacuum transmitting hose assembly.

HINT:

Make sure that the paint marks on the No. 1 and No. 2 vacuum transmitting hose assemblies and No. 1 and No. 2 vacuum pipes are aligned.

Using vernier calipers, measure the free length of the compression springs.

Minimum length:

38.5 mm (1.516 in.)

Fully insert 2 new gaskets to the exhaust manifold converter and front exhaust pipe assembly by hand.

NOTICE:

1. Be careful with the installation direction of the gasket.
   
2. Do not reuse the gasket.
   
3. Do not damage the gasket.
   
4. To ensure a proper seal, do not use the tail exhaust pipe to force the gasket onto the front exhaust pipe.
   

   HINT:

   Using a plastic hammer, uniformly strike the gasket so that the gasket and front exhaust pipe are properly fit.

Install the front exhaust pipe assembly.

Install the 2 bolts and 2 compression springs.

Torque:

43 N*m{439 kgf*cm, 32 ft.*lbf}

NOTICE:

After installation, check that the clearance is almost the same at any point between the flanges of the tail exhaust pipe assembly and front exhaust pipe assembly.

Install the 2 bolts and 2 compression springs.

Torque:

43 N*m{439 kgf*cm, 32 ft.*lbf}

NOTICE:

After installation, check that the clearance is almost the same at any point between the flanges of the exhaust manifold converter and front exhaust pipe assembly.

Install the side cover with the 2 clips.

Install the intake duct seal with the 11 clips.

Install the No. 1 engine cover.