RM38T0EC _51 Engine / Hybrid System _144997 M20F-FXS, M20G-FXS INTAKE / EXHAUST _0604324 EXHAUST PIPE A

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


CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)
A548199N01
0.573,3.094 1.323,3.26 0.75,0.167 4.375,1.896 5.125,2.063 0.75,0.167 6.375,3.198 7.125,3.365 0.75,0.167 3.698,3.052 4.531,3.385 0.833,0.333 2.51,0.927 3.344,1.26 0.833,0.333 3.76,2.177 4.594,2.51 0.833,0.333 4.719,0.99 5.052,0.99 false 5.74,2.771 6.073,2.771 false 6.031,3.292 6.365,3.292 false 1.333,3.177 1.667,3.177 false 0.458,2.052 0.458,2.385 false 1.938,3.052 1.938,3.385 false 3.125,3.073 3.323,3.24 3.323,3.24 3.323,3.406 false 5.708,0.771 5.469,1.01 5.469,1.01 5.469,1.177 false 4.042,1.969 4.375,1.969 false 1.958,2.802 2.333,1.083 2.333,1.083 2.5,1.083 true 2.365,2.885 3.583,2.333 3.583,2.333 3.75,2.333 true 0.281,0.188 0.615,0.188 false 2.656,2.063 2.75,1.667 2.75,1.667 2.917,1.667 false 3.104,2.781 3.521,3.208 3.521,3.208 3.688,3.208 false 4.698,2.771 5.031,2.771 false 2.333,3.229 2.531,3.385 2.531,3.385 2.531,3.552 false 0.677,0.031 0.958,0.385 0.281,0.354 18 false 8 5.542,1.177 5.823,1.531 0.281,0.354 18 false 6 3.24,1.531 3.521,1.885 0.281,0.354 18 false 1 3.396,3.344 3.677,3.698 0.281,0.354 18 false 3 2.583,3.479 2.854,3.771 0.271,0.292 18 false 5 2.01,3.323 2.292,3.677 0.281,0.354 18 false 2 6.146,2.635 6.427,2.99 0.281,0.354 18 false 7 0.427,2.406 0.583,2.604 0.156,0.198 10 false ● 1.479,2.844 1.792,3.042 0.313,0.198 10 false x2 1.75,3.094 2.063,3.292 0.313,0.198 10 false x2 4.021,1.969 4.333,2.167 0.313,0.198 10 false x2 4.292,1.625 4.604,1.823 0.313,0.198 10 false x2 6.115,2.896 6.427,3.094 0.313,0.198 10 false x2 6.042,3.302 6.354,3.5 0.313,0.198 10 false x8 0.656,3.104 1.594,3.302 0.938,0.198 8 false 43 (438, 32) 4.417,1.906 5.354,2.104 0.938,0.198 8 false 43 (438, 32) 6.448,3.208 7.115,3.531 0.667,0.323 8 false 29 (296, 21) 3.75,3.083 4.75,3.271 1,0.188 8 false 30 (306, 22) 3.75,3.219 4.719,3.448 0.969,0.229 8 false 26.3 (268, 19)* 2.563,0.948 3.563,1.135 1,0.188 8 false 30 (306, 22) 2.563,1.083 3.531,1.313 0.969,0.229 8 false 26.3 (268, 19)* 3.802,2.198 4.688,2.448 0.885,0.25 8 false 44 (449, 32) 3.802,2.344 4.75,2.521 0.948,0.177 8 false 37.7 (384, 28)* 5.115,0.885 5.271,1.083 0.156,0.198 10 false ● 5.083,2.615 5.365,2.969 0.281,0.354 18 false 4

Procedure Part Name Code
Z101186

Z101188

Z101187

1 FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst) 17410 (Click here) - -
2 EXHAUST GAS TEMPERATURE SENSOR 89425 (Click here) - -
3 NO. 2 EXHAUST GAS TEMPERATURE SENSOR 89425A (Click here) - -
4 COVER - - - -
5 AIR FUEL RATIO SENSOR 89467C (Click here) - -
6 TAIL EXHAUST PIPE ASSEMBLY 17430 (Click here) - -
7 FRONT FLOOR CENTER BRACE 57533B - - -
8 INSPECT FOR EXHAUST GAS LEAK - (Click here) - -

V100146

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

PROCEDURE

Hide 17410 1.INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)

a.
A470008C05
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) *2 Gasket
*a Wooden Block *b Plastic Hammer


i.

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

Standard Length 43 mm (1.69 in.)
Minimum Free Length 41.5 mm (1.63 in.)

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


ii.

Temporarily install a new gasket to the exhaust manifold (TWC: Front Catalyst).


iii.

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

NOTICE:
·

Be careful with the installation direction of the gasket.

·

Do not reuse the gasket.

·

Do not damage the gasket.

·

Do not push in the gasket by using the exhaust pipes when connecting them.





b.
A546946C01
1.688,1 1.813,0.76 true 1.719,0.396 1.844,0.552 true 2.656,0.646 2.719,0.385 true 1.563,0.292 1.875,0.448 0.313,0.156 10 false *1 1.583,1.01 1.896,1.167 0.313,0.156 10 false *2 2.667,0.219 2.979,0.375 0.313,0.156 10 false *3 1.365,1.094 1.677,1.25 0.313,0.156 10 false *a 1.021,0.24 1.427,0.615 0.406,0.375 18 false iii 2.313,1.271 2.542,1.667 0.229,0.396 18 false ii 3.552,0.073 3.76,0.365 0.208,0.292 18 true i
*1 Exhaust Manifold (TWC: Front Catalyst) *2 Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
*3 Gasket - -
*a Space between Flanges: 8.5 mm (0.335 in.) - -


i.

Connect the front exhaust pipe assembly (TWC: Rear Catalyst) 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 and front exhaust pipe assembly is consistent front-to-rear and left-to-right.



Hide 89425 2.INSTALL EXHAUST GAS TEMPERATURE SENSOR

Z101186

Click here(Click here)

Hide 89425A 3.INSTALL NO. 2 EXHAUST GAS TEMPERATURE SENSOR

Z101186

Click here(Click here)

Hide 89467C 5.INSTALL AIR FUEL RATIO SENSOR

Z101186

Click here(Click here)

Hide 17430 6.INSTALL TAIL EXHAUST PIPE ASSEMBLY

a.
A470008C03
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 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 40 mm (1.57 in.)
Minimum Free Length 38.5 mm (1.52 in.)

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


ii.

Temporarily install a new gasket to the front exhaust pipe assembly (TWC: Rear Catalyst).


iii.

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

NOTICE:
·

Be careful with the installation direction of the gasket.

·

Do not reuse the gasket.

·

Do not damage the gasket.

·

Do not push in the gasket by using the exhaust pipes when connecting them.





b.
A546947C01
2.094,0.583 1.948,0.49 false 1.885,1.323 2.063,0.781 false 3,1.469 2.896,0.833 true 1.781,0.385 2.094,0.542 0.313,0.156 10 false *2 1.813,1.333 2.125,1.49 0.313,0.156 10 false *1 2.938,1.479 3.25,1.635 0.313,0.156 10 false *3 1.615,1.125 1.927,1.281 0.313,0.156 10 false *a 1.25,0.26 1.542,0.552 0.292,0.292 18 false iii 2.375,1.396 2.625,1.656 0.25,0.26 18 false ii 3.313,0.021 3.563,0.281 0.25,0.26 18 true i
*1 Front Exhaust Pipe Assembly (TWC: Rear Catalyst) *2 Tail Exhaust Pipe Assembly
*3 Gasket - -
*a Space between Flanges: 6.5 mm (0.256 in.) - -


i.

Connect the tail exhaust pipe assembly to the 3 exhaust pipe supports.


ii.

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



Hide 8.INSPECT FOR EXHAUST GAS LEAK

a.
A460669N04
0.542,0.115 0.823,0.469 0.281,0.354 18 false i

i.

If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.

HINT:

Perform "Inspection After Repairs" after repairing or replacing the exhaust system.

Click hereEngine / Hybrid System>M20F-FXS, M20G-FXS (ENGINE CONTROL)>SFI SYSTEM>INITIALIZATION