Replacement
REPLACEMENTNOTE: Check if an old gasket still remains on the pipe. If so, remove it. Also, check if any bolts or nuts are rusted. If so, replace them.
1. REMOVE FRONT EXHAUST PIPE
a. Remove the 2 bolts and 2 compression springs.
b. Remove the 2 bolts and exhaust pipe.
c. Remove the exhaust pipe's gasket and exhaust manifold's gasket.
2. REMOVE CENTER EXHAUST PIPE
a. Remove the heated oxygen sensor (bank 1 sensor 2).
b. Remove the 2 bolts from the exhaust pipe.
c. Remove the exhaust pipe from the 2 rings.
d. Remove the gasket from the exhaust pipe.
3. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
a. Disconnect the A/F sensor connector (bank 1 sensor 1).
b. Remove the 3 bolts, nut and No. 1 exhaust manifold heat insulator.
c. Remove the A/F sensor (bank 1 sensor 1) from the exhaust manifold.
4. REMOVE EXHAUST MANIFOLD (w/ TWC)
a. Remove the 2 bolts, 2 nuts and 2 exhaust manifold stays.
b. Remove the 5 nuts and exhaust manifold.
c. Remove the gasket from the cylinder head.
5. INSPECT EXHAUST MANIFOLD (w/ TWC)
Using a precision straight edge and feeler gauge, measure the manifold surface contacting the cylinder head for warpage.
Maximum warpage: 0.70 mm (0.0276 in.)
If the warpage is greater than the maximum, replace the manifold.
6. REMOVE HEAT INSULATORS
a. Remove the 3 bolts and No. 1 manifold converter heat insulator.
b. Remove the 2 bolts and No. 2 manifold converter heat insulator.
c. Remove the 2 bolts and No. 2 exhaust manifold heat insulator.
7. INSTALL HEAT INSULATORS
a. Install the No. 2 exhaust manifold heat insulator with the 2 bolts.
Torque:12 N.m (122kgf.cm, 9 ft.lbf)
b. Install the No. 2 exhaust converter heat insulator with the 2 bolts.
Torque:12 N.m (122kgf.cm, 9 ft.lbf)
c. Install the No. 1 manifold converter heat insulator with the 3 bolts.
Torque:12 N.m (122kgf.cm, 9 ft.lbf)
8. INSTALL EXHAUST MANIFOLD (w/ TWC)
a. Install a new gasket to the cylinder head.
b. Install the exhaust manifold with the 5 nuts. Uniformly tighten the 5 nuts in the order shown in the illustration.
Torque:37 N.m (377 kgf.cm, 27 ft.lbf)
c. Install the 2 exhaust manifold stays with the 2 bolts and 2 nuts.
Torque:44 N.m (449 kgf.cm, 32 ft.lbf)
9. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
a. Install the A/F sensor (bank 1 sensor 1) to the exhaust manifold.
Torque:44 N.m (449 kgf.cm, 32 ft.lbf)
b. Install the No. 1 exhaust manifold heat insulator with the 3 bolts and nut.
Torque:12 N.m (122kgf.cm, 9 ft.lbf)
c. Connect the A/F sensor connector (bank 1 sensor 1).
10. INSTALL CENTER EXHAUST PIPE
a. Install a new gasket to the exhaust pipe.
NOTE:
- Do not reuse the gasket.
- The gasket must be installed to the exhaust pipe before the pipe is installed to the tailpipe. Do not indirectly use the tailpipe to force the gasket onto the exhaust pipe.
b. Install the exhaust pipe to the 2 rings.
c. Install the 2 bolts to the exhaust pipe.
Torque: 49 N.m (500 kgf.cm, 36 ft.lbf)
d. Install the heated oxygen sensor (bank 1 sensor 2).
Torque: 44 N.m (449 kgf.cm, 32 ft.lbf)
HINT:
- Before installing the heated oxygen sensor, twist the sensor wire counterclockwise 3 and 1/2 turns.
- After installing the heated oxygen sensor, check that the sensor wire is not twisted. If it is twisted, remove the heated oxygen sensor and reinstall it.
11. INSTALL FRONT EXHAUST PIPE
a. Using a vernier caliper, measure the free length of the compression spring.
Minimum length: 40 mm (1.57 in.)
If the free length is less than the minimum, replace the compression spring.
b. Install a new gasket to the front exhaust pipe.
NOTE:
- Do not reuse the gasket.
- The gasket must be installed to the front exhaust pipe before the pipe is installed to the center exhaust pipe. Do not indirectly use the center exhaust pipe to force the gasket onto the front exhaust pipe.
c. Install a new gasket to the exhaust manifold.
NOTE:
- Using a plastic faced hammer, uniformly strike the gasket so that the gasket and exhaust manifold are properly fit.
- Be careful with the installation direction of the gasket.
- Do not reuse the gasket.
- The gasket must be installed to the exhaust manifold before the manifold is installed to the exhaust pipe. Do not indirectly use the exhaust pipe to force the gasket onto the exhaust manifold.
d. Temporarily install the 2 compression springs and 2 bolts holding the exhaust manifold to the front exhaust manifold pipe.
e. Install the front exhaust pipe to the center exhaust pipe with the 2 bolts.
Torque: 49 N.m (500 kgf.cm, 36 ft.lbf)
f. Tighten the 2 compression springs and 2 bolts.
Torque: 43 N.m (439 kgf.cm, 32 ft.lbf)
12. CHECK FOR EXHAUST GAS LEAKS
If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.