RM38T0EC _51 Engine / Hybrid System _144997 M20F-FXS, M20G-FXS INTAKE / EXHAUST _0604323 EXHAUST MANIFOLD A

M20F-FXS, M20G-FXS INTAKE / EXHAUST  EXHAUST MANIFOLD  INSTALLATION  


CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)
A546937N01
0.917,1.417 1.75,1.583 0.833,0.167 0.51,2.969 1.344,3.135 0.833,0.167 2.573,1.26 3.406,1.427 0.833,0.167 4.01,0.344 4.844,0.51 0.833,0.167 4.583,2.74 5.417,2.906 0.833,0.167 5.25,0.583 6.333,0.917 1.083,0.333 5.583,1.531 6.5,1.865 0.917,0.333 1.552,0.938 1.885,0.938 false 1.031,2.458 1.365,2.458 false 1.344,3.052 1.677,3.052 false 6.25,2.417 6.583,2.417 false 4.885,1.292 5.219,1.292 false 2.104,1.99 1.917,1.5 1.917,1.5 1.75,1.5 false 1.781,2.344 1.583,1.917 1.583,1.917 1.417,1.917 false 4.302,2.583 4.417,2.833 4.417,2.833 4.583,2.833 false 4.521,2.281 4.583,2.417 4.583,2.417 4.75,2.417 false 4.708,1.76 4.917,1.917 4.917,1.917 5.083,1.917 false 5.01,0.99 5.083,0.75 5.083,0.75 5.25,0.75 false 3.76,0.75 3.833,0.417 3.833,0.417 4,0.417 false 3.969,1.625 3.583,1.333 3.583,1.333 3.417,1.333 false 4.99,1.448 5.417,1.708 5.417,1.708 5.583,1.708 false 1.365,0.792 1.646,1.146 0.281,0.354 18 false 2 1.229,0.854 1.385,1.052 0.156,0.198 10 false ● 1.24,1.813 1.521,2.167 0.281,0.354 18 false 3 0.854,2.333 1.135,2.688 0.281,0.354 18 false 1 5.583,1.177 5.865,1.531 0.281,0.354 18 false 5 5.125,2.24 5.406,2.594 0.281,0.354 18 false 2 5.156,1.74 5.438,2.094 0.281,0.354 18 false 4 6.677,2.292 6.958,2.646 0.281,0.354 18 false 6 1.771,2.99 2.083,3.188 0.313,0.198 10 false x3 4.021,1.646 4.333,1.844 0.313,0.198 10 false x7 3.823,0.708 4.135,0.906 0.313,0.198 10 false x3 1.052,1.427 1.885,1.625 0.833,0.198 8 false 43 (438, 32) 2.458,1.25 2.615,1.448 0.156,0.198 10 false ● 4.667,2.75 5.5,2.948 0.833,0.198 8 false 43 (438, 32) 0.656,2.979 2.01,3.135 1.354,0.156 8 false 11 (112, 8) 2.656,1.271 4.125,1.427 1.469,0.156 8 false 26 (265, 19) 4.135,0.354 5.49,0.51 1.354,0.156 8 false 10 (102, 7) 5.302,0.594 6.656,0.75 1.354,0.156 8 false 10 (102, 7) 5.323,0.75 6.615,1 1.292,0.25 8 false 8.8 (90, 78 in.*lbf)* 5.646,1.552 7,1.708 1.354,0.156 8 false 30 (306, 22) 5.646,1.688 7,1.844 1.354,0.156 8 false 26.3 (268, 19)*

Procedure Part Name Code
Z101186

Z101188

Z101187

1 NO. 2 EXHAUST MANIFOLD HEAT INSULATOR 17168 - - -
2 EXHAUST MANIFOLD (TWC: Front Catalyst) 17141 (Click here) - -
3 MANIFOLD STAY 17118 (Click here) - -
4 NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 17167 - - -
5 NO. 1 VACUUM PIPE - (Click here) - -
6 AIR FUEL RATIO SENSOR 89467B - - -

V100146

N*m (kgf*cm, ft.*lbf): Specified torque * For use with a union nut wrench
● Non-reusable part - -

A546940N01
2.667,1.167 3.667,1.333 1,0.167 0.083,3.667 1.083,3.833 1,0.167 5.75,3.333 6.417,3.5 0.667,0.167 4.094,3.844 4.76,4.01 0.667,0.167 4.906,4.833 5.573,5 0.667,0.167 4.063,1.323 3.833,1.25 3.833,1.25 3.667,1.25 false 0.51,3.125 0.583,3.5 0.583,3.5 0.583,3.667 false 2.875,3.167 2.75,3 2.75,3 2.583,3 false 6.083,3.167 6.083,3.333 false 3.865,4.167 3.917,3.917 3.917,3.917 4.083,3.917 false 5.573,4.635 5.906,4.635 false 1.167,2.417 1.333,2.167 1.333,2.167 1.5,2.167 false 4.969,0.896 5.302,0.896 false 4.948,3.469 5.083,3.667 5.083,3.667 5.25,3.667 false 6.521,0.24 6.854,0.24 false 5.583,4.917 5.75,4.917 5.75,4.917 6.073,5.01 false 5.208,4.083 5.542,4.083 false 6.469,2.333 6.802,2.333 false 6.354,2.865 6.667,3.063 0.313,0.198 10 false x2 6.146,3.135 6.458,3.333 0.313,0.198 10 false x2 4.167,0.865 4.5,1.135 0.333,0.271 10 false x3 6.208,4.958 6.521,5.156 0.313,0.198 10 false x8 1.313,3.354 1.625,3.552 0.313,0.198 10 false x10 3.875,4.219 4.188,4.417 0.313,0.198 10 false x2 3.479,4.073 3.792,4.271 0.313,0.198 10 false x2 0.594,3.042 0.906,3.24 0.313,0.198 10 false x4 5.781,3.344 6.479,3.5 0.698,0.156 8 false 43 (438, 32) 4.938,4.844 5.635,5 0.698,0.156 8 false 29 (296, 21) 4.115,3.854 4.813,4.01 0.698,0.156 8 false 43 (438, 32) 0.135,3.667 1.115,3.833 0.979,0.167 8 false 7.5 (76, 66 in.*lbf) 2.729,1.177 3.708,1.344 0.979,0.167 8 false 5.0 (51, 44 in.*lbf) 2.448,2.917 2.76,3.115 0.313,0.198 10 false ● 6.875,2.24 7.104,2.448 0.229,0.208 10 false ● 1.583,2 1.969,2.281 0.385,0.281 18 false 12 5.344,0.771 5.677,1.135 0.333,0.365 18 false 7 5.5,3.573 5.917,3.938 0.417,0.365 18 false 8 5.604,3.948 6.021,4.313 0.417,0.365 18 false 9 5.25,4.51 5.635,4.854 0.385,0.344 18 false 10 6.177,0.115 6.563,0.458 0.385,0.344 18 false 11 6.281,4.635 6.594,4.833 0.313,0.198 10 false x2 4.198,1.281 4.51,1.479 0.313,0.198 10 false x3

Procedure Part Name Code
Z101186

Z101188

Z101187

7 FRONT NO. 1 FLOOR HEAT INSULATOR 58151 - - -
8 FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst) 17410 (Click here) - -
9 COVER - - - -
10 FRONT FLOOR CENTER BRACE 57533B - - -
11 INSPECT FOR EXHAUST GAS LEAK - (Click here) - -
12 NO. 1 ENGINE UNDER COVER ASSEMBLY 51410 - - -

V100146

N*m (kgf*cm, ft.*lbf): Specified torque ● Non-reusable part

PROCEDURE

Hide 17168 1.INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

Torque:
11 N*m (112 kgf*cm, 8 ft.*lbf)

Hide 17141 2.INSTALL EXHAUST MANIFOLD (TWC: Front Catalyst)

a.
A546941N01
1.948,0.052 2.229,0.406 0.281,0.354 18 false i 0.375,2.021 0.656,2.375 0.281,0.354 18 false ii 3.844,2.042 4.125,2.396 0.281,0.354 18 false iii 4.656,2.094 4.802,2.281 0.146,0.188 10 true 7 4.875,2.667 5.01,2.885 0.135,0.219 10 true 6 5.479,2.656 5.615,2.875 0.135,0.219 10 true 4 5.948,2.563 6.094,2.813 0.146,0.25 10 true 1 6.385,2.531 6.531,2.781 0.146,0.25 10 true 5 6.198,1.948 6.344,2.198 0.146,0.25 10 true 3 5.156,1.969 5.302,2.188 0.146,0.219 10 true 2

i.

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


ii.

Using a 12 mm deep socket wrench, temporarily install the exhaust manifold (TWC: Front Catalyst) to the cylinder head sub-assembly with 7 new nuts.


iii.

Using the 12 mm deep socket wrench, tighten the 7 nuts in the order shown in the illustration.

Torque:
26 N*m (265 kgf*cm, 19 ft.*lbf)



Hide 17118 3.INSTALL MANIFOLD STAY

a.
A483301N04
0.417,0.021 0.698,0.375 0.281,0.354 18 false i 3.74,0.01 3.906,0.365 0.167,0.354 18 false ii 6.177,0.406 6.354,0.615 0.177,0.208 10 true 1 4.177,0.354 4.354,0.563 0.177,0.208 10 true 2

i.

Temporarily install the manifold stay to the exhaust manifold (TWC: Front Catalyst) and cylinder block sub-assembly with the bolt and nut.


ii.

Tighten the bolt and nut in the order shown in the illustration.

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



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

Torque:
10 N*m (102 kgf*cm, 7 ft.*lbf)

Hide 5.INSTALL NO. 1 VACUUM PIPE

a.
A528786C03
2.854,1.146 2.969,0.99 false 0.427,0.094 1.802,0.448 1.375,0.354 18 false i, ii 1.865,0.76 2.24,0.969 0.375,0.208 10 false *b 2.938,0.781 3.313,0.99 0.375,0.208 10 false *a
*a Union Nut Wrench *b Torque Wrench Fulcrum Length


i.

Using a 14 mm union nut wrench, connect the No. 1 vacuum pipe to the exhaust manifold (TWC: Front Catalyst).

Torque:
30 N*m (306 kgf*cm, 22 ft.*lbf)

HINT:
·

Using a 14 mm union nut wrench, connect the No. 1 vacuum pipe to the exhaust manifold (TWC: Front Catalyst).

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION

·

When using a 14 mm union nut wrench (fulcrum length of 25 mm (0.866 in.)) + torque wrench (fulcrum length of 180 mm (6.38 in.)): 26.3 N*m (268 kgf*cm, 19 ft.*lbf)




ii.

Install the No. 1 vacuum pipe to the exhaust manifold (TWC: Front Catalyst) with the nut.

Torque:
10 N*m (102 kgf*cm, 7 ft.*lbf)

HINT:

When using a 10 mm union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 155 mm (6.1 in.)): 8.8 N*m (90 kgf*cm, 78 in.*lbf)




Hide 17410 8.INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)

a.
A470008C04
1.531,2.292 1.719,1.979 1.719,1.979 1.865,1.979 false 1.708,3.229 1.594,3.594 1.594,3.594 1.427,3.594 true 4.958,2.292 5.146,1.979 5.146,1.979 5.292,1.979 false 5.094,3.219 5.052,3.573 5.052,3.573 4.885,3.573 true 5.448,2.302 5.708,2.146 5.708,2.146 5.854,2.146 false 5.99,2.719 6.271,2.396 6.271,2.396 6.417,2.396 true 1.906,1.865 2.219,2.021 0.313,0.156 10 false *1 1.25,3.5 1.563,3.656 0.313,0.156 10 false *2 5.896,2.031 6.208,2.188 0.313,0.156 10 false *a 6.448,2.292 6.76,2.448 0.313,0.156 10 false *b 5.344,1.865 5.656,2.021 0.313,0.156 10 false *1 4.698,3.469 5.01,3.625 0.313,0.156 10 false *2 2.313,0.135 2.604,0.417 0.292,0.281 18 false i 0.51,2.063 0.802,2.344 0.292,0.281 18 false ii 4.25,2.052 4.542,2.333 0.292,0.281 18 false iii
*1 Exhaust Manifold (TWC: Front Catalyst) or Front Exhaust Pipe Assembly (TWC: Rear Catalyst) *2 Gasket
*a Wooden Block *b Plastic Hammer


i.

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

Standard Length (Front) 43 mm (1.69 in.)
Standard Length (Rear) 40 mm (1.57 in.)
Minimum Free Length (Front) 41.5 mm (1.63 in.)
Minimum Free Length (Rear) 38.5 mm (1.52 in.)

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


ii.

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


iii.

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

NOTICE:
·

Be sure to install the gasket 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.





b.
A546942C01
0.844,2.021 0.698,1.896 true 1.646,2.24 1.688,2.615 true 3.552,2.26 3.594,2.635 true 2.75,2.021 2.604,1.896 true 0.823,2.188 0.698,2.26 true 2.719,2.177 2.594,2.26 true 0.271,0.125 0.49,0.448 0.219,0.323 18 true i 1.198,2.594 1.417,2.917 0.219,0.323 18 false iii 3.125,2.583 3.344,2.906 0.219,0.323 18 false v 4.031,0.135 4.667,0.438 0.635,0.302 18 true vi, vii 0.677,2.948 1.365,3.281 0.688,0.333 18 true viii, ix 3.979,2.938 4.719,3.271 0.74,0.333 18 true x, xi 0.531,1.802 0.844,1.958 0.313,0.156 10 false *1 2.427,2.208 2.74,2.365 0.313,0.156 10 false *2 2.438,1.802 2.75,1.958 0.313,0.156 10 false *3 3.542,2.646 3.854,2.802 0.313,0.156 10 false *4 0.406,2.646 0.719,2.802 0.313,0.156 10 false *a 2.313,2.635 2.625,2.792 0.313,0.156 10 false *b 1.635,2.625 1.948,2.781 0.313,0.156 10 false *4 0.531,2.198 0.844,2.375 0.313,0.177 10 false *2 0.135,0.771 0.333,1.115 0.198,0.344 18 true ii 3.49,1.229 3.813,1.594 0.323,0.365 18 true iv
*1 Exhaust Manifold (TWC: Front Catalyst) *2 Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
*3 Tail Exhaust Pipe Assembly *4 Gasket
*a Space between Flanges: 8.5 mm (0.335in.) *b Space between Flanges: 6.5 mm (0.256in.)


i.

Connect the front exhaust pipe assembly to the 2 exhaust pipe supports.


ii.

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

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


iii.

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


iv.

Install the front exhaust pipe assembly (TWC: 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)


v.

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


vi.

Engage the wire harness clamp.


vii.

Connect the heated oxygen sensor connector.


viii.

Engage the 3 wire harness clamps.


ix.

Connect the exhaust gas temperature sensor connector.


x.

Engage the wire harness clamp.


xi.

Connect the exhaust gas temperature sensor connector.



Hide 57533B 10.INSTALL FRONT FLOOR CENTER BRACE

Torque:
29 N*m (296 kgf*cm, 21 ft.*lbf)