EXHAUST MANIFOLD (for Hatchback) > INSTALLATION |
1. INSTALL EXHAUST MANIFOLD TO HEAD GASKET |
Install the new exhaust manifold to head gasket to the cylinder head assembly.
2. INSTALL EXHAUST MANIFOLD |
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 |
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 |
Install the No. 1 exhaust manifold heat insulator with the 4 bolts.
- Torque:
- 8.0 N*m{ 82 kgf*cm , 71 in.*lbf }
Install the wire harness bracket with the bolt.
- Torque:
- 61 N*m{ 622 kgf*cm , 45 ft.*lbf }
Engage the 2 wire harness clamps and install the wire harness.
5. INSTALL ENGINE MOVING CONTROL ROD |
Install the engine moving control rod with the bolt.
- Torque:
- 120 N*m{ 1224 kgf*cm , 89 ft.*lbf }
6. INSTALL EXHAUST PIPE GASKET |
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:
- Install the gasket in the correct direction.
- Do not reuse the gasket.
- Do not damage the gasket by dropping it, etc.
- Do not damage the outer surface of the gasket.
- Do not push in the gasket with the exhaust pipe when connecting it.
7. INSTALL NO. 2 EXHAUST PIPE GASKET |
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:
- Install the gasket in the correct direction.
- Do not reuse the gasket.
- Do not damage the gasket by dropping it, etc.
- Do not damage the outer surface of the gasket.
- Do not push in the gasket with the exhaust pipe when connecting it.
8. INSTALL FRONT EXHAUST PIPE ASSEMBLY |
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.
Hang the front exhaust pipe assembly with the 3 exhaust pipe supports.
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.
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.
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.
Pass the connector through the hole into the inside of the vehicle and install the oxygen sensor wire grommet.
Connect the oxygen sensor connector.
9. INSTALL FRONT FLOOR CENTER BRACE |
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 |
11. INSTALL AIR FUEL RATIO SENSOR |
12. INSPECT FOR EXHAUST GAS LEAK |
- HINT:
- Perform "Inspection After Repairs" after repairing or replacing the exhaust system (Click here).