EXHAUST MANIFOLD (for Hatchback) > INSTALLATION



1. INSTALL EXHAUST MANIFOLD TO HEAD GASKET
  1. Install the new exhaust manifold to head gasket to the cylinder head assembly.



2. INSTALL EXHAUST MANIFOLD


    A254827E02
  1. Install the exhaust manifold with the 3 bolts and 2 nuts in the order shown in the illustration.

    Torque:
    27 N*m{ 275 kgf*cm , 20 ft.*lbf }


3. INSTALL MANIFOLD SUPPORT BRACKET
  1. Install the manifold support bracket with the 3 bolts.

    Torque:
    44 N*m{ 449 kgf*cm , 32 ft.*lbf }


4. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
  1. Install the No. 1 exhaust manifold heat insulator with the 4 bolts.

    Torque:
    8.0 N*m{ 82 kgf*cm , 71 in.*lbf }
  1. Install the wire harness bracket with the bolt.

    Torque:
    61 N*m{ 622 kgf*cm , 45 ft.*lbf }
  1. Engage the 2 wire harness clamps and install the wire harness.



5. INSTALL ENGINE MOVING CONTROL ROD
  1. Install the engine moving control rod with the bolt.

    Torque:
    120 N*m{ 1224 kgf*cm , 89 ft.*lbf }


6. INSTALL EXHAUST PIPE GASKET


    A128852E04
  1. Using a plastic hammer and a wooden block, tap in a new exhaust pipe gasket until its surface is flush with the exhaust manifold.

    Text in Illustration 
    *1
    Exhaust Pipe Gasket
    *2
    Wooden Block
    *3
    Plastic Hammer
    *4
    Exhaust Manifold

    NOTICE:
    1. Install the gasket in the correct direction.
    2. Do not reuse the gasket.
    3. Do not damage the gasket by dropping it, etc.
    4. Do not damage the outer surface of the gasket.
    5. Do not push in the gasket with the exhaust pipe when connecting it.


7. INSTALL NO. 2 EXHAUST PIPE GASKET


    A128852E04
  1. Using a plastic hammer and a wooden block, tap in a new No. 2 exhaust pipe gasket until its surface is flush with the front exhaust pipe assembly.

    Text in Illustration 
    *1
    No. 2 Exhaust Pipe Gasket
    *2
    Wooden Block
    *3
    Plastic Hammer
    *4
    Front Exhaust Pipe Assembly

    NOTICE:
    1. Install the gasket in the correct direction.
    2. Do not reuse the gasket.
    3. Do not damage the gasket by dropping it, etc.
    4. Do not damage the outer surface of the gasket.
    5. Do not push in the gasket with the exhaust pipe when connecting it.


8. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    A128853
  1. Using a vernier caliper, measure the free length of the compression spring.

    Minimum Length:
    41.5 mm (1.634 in.)

    HINT:
    If the length is not as specified, replace the compression spring.
  1. Hang the front exhaust pipe assembly with the 3 exhaust pipe supports.



    A247549J01
  1. Install the front exhaust pipe assembly onto the exhaust manifold with the 2 compression springs and 2 bolts.

    Text in Illustration 
    *1
    Exhaust Manifold
    *2
    Front Exhaust Pipe Assembly
    *3
    Exhaust Pipe Gasket
    *a
    Space between flanges: 8.5 mm (0.335 in.)

    Torque:
    43 N*m{ 438 kgf*cm , 32 ft.*lbf }

    HINT:
    After the installation, check that the gaps between the flanges of the exhaust manifold and front exhaust pipe assembly are consistent front-to-rear and left-to-right.


    A128853
  1. Using a vernier caliper, measure the free length of the compression spring.

    Minimum Length:
    38.5 mm (1.516 in.)

    HINT:
    If the length is not as specified, replace the compression spring.


    A247551J01
  1. Connect the tail exhaust pipe assembly to the front exhaust pipe assembly with the 2 compression springs and 2 bolts.

    Text in Illustration 
    *1
    Front Exhaust Pipe Assembly
    *2
    Tail Exhaust Pipe Assembly
    *3
    No. 2 Exhaust Pipe Gasket
    *a
    Space between flanges: 6.5 mm (0.256 in.)

    Torque:
    43 N*m{ 438 kgf*cm , 32 ft.*lbf }

    HINT:
    After the installation, check that the gaps between the flanges of the front exhaust pipe assembly and tail exhaust pipe assembly are consistent front-to-rear and left-to-right.
  1. Pass the connector through the hole into the inside of the vehicle and install the oxygen sensor wire grommet.

  1. Connect the oxygen sensor connector.



9. INSTALL FRONT FLOOR CENTER BRACE
  1. Install the front floor center brace onto the body with the 2 bolts.

    Torque:
    30 N*m{ 307 kgf*cm , 22 ft.*lbf }


10. INSTALL REAR CONSOLE BOX ASSEMBLY
(Click here)


11. INSTALL AIR FUEL RATIO SENSOR
(Click here)


12. INSPECT FOR EXHAUST GAS LEAK

HINT:
Perform "Inspection After Repairs" after repairing or replacing the exhaust system (Click here).