2NZ-FE INTAKE / EXHAUST  EXHAUST MANIFOLD  INSTALLATION  


PROCEDURE

Hide 17141 1.INSTALL EXHAUST MANIFOLD

a.

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


b.

Temporarily install the exhaust manifold to the cylinder head sub-assembly with the 3 bolts and 2 nuts.


c.
A324802C02
2.021,0.042 2.219,0.354 0.198,0.313 10 false 1 0.344,0.031 0.573,0.26 0.229,0.229 10 false 4 3.052,0.021 3.313,0.313 0.26,0.292 10 false 5 0.771,1 0.938,1.198 0.167,0.198 10 true 2 2.375,1.042 2.563,1.271 0.188,0.229 10 true 3
V100135

Bolt
V100136

Nut


Tighten the 3 bolts and 2 nuts in the order shown in the illustration.

Torque:
27 N*m (275 kgf*cm, 20 ft.*lbf)


Hide 25591 2.INSTALL MANIFOLD SUPPORT BRACKET

a.

Temporarily install the manifold support bracket to the exhaust manifold and cylinder block sub-assembly with the 3 bolts.


b.
A171147E01
2.646,1.042 2.802,1.24 0.156,0.198 10 true 1 2.823,1.552 2.979,1.75 0.156,0.198 10 true 2 1.573,1.219 1.729,1.417 0.156,0.198 10 true 3

Tighten the 3 bolts in the order shown in the illustration.

Torque:
44 N*m (449 kgf*cm, 32 ft.*lbf)


Hide 17410 3.INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Front and Rear Catalyst)

a.
A128853

Using a vernier caliper, measure the free length of the compression springs.

Minimum (front) 41.5 mm (1.63 in.)
Minimum (rear) 38.5 mm (1.52 in.)

If the free length is less than minimum, replace the compression spring.


b.

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


c.
A181728C66
2.927,1.385 2.802,1.385 2.802,1.385 2.5,1.698 false 1.781,3.26 2.021,3.26 2.021,3.26 2.021,2.438 false 1.125,0.552 1.448,0.552 1.448,0.552 1.448,1.625 false 0.896,0.5 1.125,0.688 0.229,0.188 10 false *1 1.583,3.177 1.854,3.385 0.271,0.208 10 false *2 3.01,1.313 3.26,1.5 0.25,0.188 10 false *a
*1 Exhaust Manifold or Front Exhaust Pipe Assembly (TWC: Front and Rear Catalyst)
*2 Gasket
*a Wooden Block


Using a plastic hammer and wooden block, tap in each gasket until its surface is flush with the exhaust manifold and front exhaust pipe assembly (TWC: Front and Rear Catalyst).

NOTICE:
·

Be sure to install the gaskets 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.




d.

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


e.
A258941C31
2.406,0.781 2.51,0.156 2.51,0.156 2.677,0.156 false 0.771,0.229 0.906,0.229 0.906,0.229 1.156,0.604 false 0.781,1.188 0.938,1.188 0.938,1.188 1.073,0.885 false 0.406,1.417 0.802,1.615 0.396,0.198 10 false *a 0.604,0.167 0.99,0.396 0.385,0.229 10 false *1 0.573,1.104 0.927,1.26 0.354,0.156 10 false *2 2.719,0.083 3.094,0.271 0.375,0.188 10 false *3
*1 Exhaust Manifold
*2 Front Exhaust Pipe Assembly (TWC: Front and Rear Catalyst)
*3 Gasket
*a Space between Flanges: 8.5 mm (0.335 in.)


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

Torque:
43 N*m (438 kgf*cm, 32 ft.*lbf)

HINT:

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



f.
A258966C21
0.833,0.438 1.063,0.438 1.063,0.438 1.354,0.938 false 2.229,0.958 2.635,0.406 2.635,0.406 2.813,0.406 false 0.927,1.51 1.104,1.51 1.104,1.51 1.323,1.156 false 0.594,1.719 0.896,1.885 0.302,0.167 10 false *a 0.656,0.365 1.094,0.552 0.438,0.188 10 false *1 0.75,1.438 1.063,1.615 0.313,0.177 10 false *2 2.844,0.333 3.208,0.51 0.365,0.177 10 false *3
*1 Tail Exhaust Pipe Assembly
*2 Front Exhaust Pipe Assembly (TWC: Front and Rear Catalyst)
*3 Gasket
*a Space between Flanges: 6.5 mm (0.256 in.)


Install the front exhaust pipe assembly (TWC: Front and 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: Front and Rear Catalyst) and tail exhaust pipe assembly are consistent front-to-rear and left-to-right.



Hide 17167 4.INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

a.

Install the No. 1 exhaust manifold heat insulator to the exhaust manifold with the 3 bolts.

Torque:
8.0 N*m (82 kgf*cm, 71 in.*lbf)


Hide 55701J 7.INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

Hide 55737B 8.INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL

Hide 55734A 9.INSTALL WATER GUARD PLATE RH

Hide 10.INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY