RM35X0E _51 Engine / Hybrid System _079308 7GR-FKS INTAKE / EXHAUST _0385727 EXHAUST MANIFOLD A

7GR-FKS INTAKE / EXHAUST  EXHAUST MANIFOLD  INSTALLATION  


PROCEDURE

Hide 17168 1.INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR (w/o Secondary Air Injection System)

a.

Install the No. 2 exhaust manifold heat insulator to the exhaust manifold assembly LH with the 2 bolts.

Torque:
13 N*m (133 kgf*cm, 10 ft.*lbf)


Hide 17150 3.INSTALL EXHAUST MANIFOLD ASSEMBLY LH

a.

Install a new gasket to the cylinder head LH.

NOTICE:

Be careful of the installation direction.



b.

w/o Secondary Air Injection System:

i.

Temporarily install the exhaust manifold assembly LH with the 4 nuts.


ii.
A437899E01
0.76,0.104 0.917,0.302 0.156,0.198 10 true 3 1.458,0.073 1.615,0.271 0.156,0.198 10 true 1 0.625,1.802 0.781,2 0.156,0.198 10 true 2 1.5,1.792 1.656,1.99 0.156,0.198 10 true 4

Tighten the 4 nuts in the sequence shown in the illustration.

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


iii.

Connect the air fuel ratio sensor connector and attach the wire harness clamp.



c.

w/ Secondary Air Injection System:

i.

Temporarily install the exhaust manifold assembly LH with the 6 nuts.


ii.
A437914E01
0.302,0.177 0.51,0.333 0.208,0.156 10 true 5 1.833,1.667 2.042,1.823 0.208,0.156 10 true 4 0.573,1.573 0.781,1.729 0.208,0.156 10 true 2 2.021,0.115 2.229,0.271 0.208,0.156 10 true 6 1.594,0.104 1.802,0.26 0.208,0.156 10 true 1 1.042,0.125 1.25,0.281 0.208,0.156 10 true 3

Tighten the 6 nuts in the sequence shown in the illustration.

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


iii.

Connect the air fuel ratio sensor connector and attach the wire harness clamp.



Hide 17362 4.INSTALL NO. 2 AIR TUBE (w/ Secondary Air Injection System)

a.
A437913C01
1.927,0.26 2.083,0.458 0.156,0.198 10 false .
V100135

Bolt
V100136

Nut


Install 2 new gaskets and the No. 2 air tube to the exhaust manifold assembly LH and No. 2 emission control valve set with the 2 bolts and 2 nuts.

Torque:
20 N*m (204 kgf*cm, 15 ft.*lbf)

NOTICE:

Do not reuse the gasket.



Hide 17119 5.INSTALL NO. 2 MANIFOLD STAY

a.

Temporarily install the No. 2 manifold stay to the transmission assembly and exhaust manifold assembly LH with the 3 bolts.


b.
A441049C02
0.125,0.073 0.438,0.229 0.313,0.156 10 true *A 0.104,2.5 0.417,2.656 0.313,0.156 10 true *B 1.948,2.083 2.104,2.281 0.156,0.198 10 true 1 2.198,4.427 2.354,4.625 0.156,0.198 10 true 1 2.219,4.417 2.375,4.615 0.156,0.198 10 true 1 1.292,3.104 1.448,3.302 0.156,0.198 10 true 2 1.146,0.625 1.302,0.823 0.156,0.198 10 true 2 1.406,0.115 1.563,0.313 0.156,0.198 10 true 3 1.479,2.521 1.635,2.719 0.156,0.198 10 true 3
*A w/ Secondary Air Injection System
*B w/o Secondary Air Injection System


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

Torque:
40 N*m (408 kgf*cm, 30 ft.*lbf)


Hide 17140 7.INSTALL EXHAUST MANIFOLD ASSEMBLY RH

a.

Install a new gasket to the cylinder head assembly RH.

NOTICE:

Be careful of the installation direction.



b.

w/ Secondary Air Injection System:

i.

Temporarily install the exhaust manifold assembly RH with the 6 nuts.


ii.
A437912E01
2.5,0.083 2.656,0.281 0.156,0.198 10 true 3 1.885,0.083 2.031,0.292 0.146,0.208 10 true 1 3.042,0.146 3.188,0.354 0.146,0.208 10 true 5 2.49,1.521 2.635,1.729 0.146,0.208 10 true 2 1.302,1.656 1.448,1.865 0.146,0.208 10 true 4 1.167,0.115 1.313,0.323 0.146,0.208 10 true 6

Tighten the 6 nuts in the sequence shown in the illustration.

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


iii.

Connect the air fuel ratio sensor connector and attach the 2 wire harness clamps.



c.

w/o Secondary Air Injection System:

i.

Temporarily install the exhaust manifold assembly RH with the 5 nuts.


ii.
A437897E01
1.667,0.156 1.854,0.323 0.188,0.167 10 true 1 2.49,0.094 2.677,0.26 0.188,0.167 10 true 4 1.521,1.906 1.708,2.073 0.188,0.167 10 true 3 2.177,1.927 2.365,2.094 0.188,0.167 10 true 5 3.125,1.771 3.313,1.938 0.188,0.167 10 true 2

Tighten the 5 nuts in the sequence shown in the illustration.

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


iii.

Connect the air fuel ratio sensor connector and attach the wire harness clamp.



Hide 17361N 8.INSTALL NO. 1 AIR TUBE (w/ Secondary Air Injection System)

a.
A437911C01
2.281,0.406 2.438,0.604 0.156,0.198 10 false .
V100135

Bolt
V100136

Nut


Install 2 new gaskets and the No. 1 air tube to the exhaust manifold assembly RH and No. 1 emission control valve set with the 2 bolts and 2 nuts.

Torque:
20 N*m (204 kgf*cm, 15 ft.*lbf)

NOTICE:

Do not reuse the gasket.



Hide 17118 10.INSTALL MANIFOLD STAY

a.

Temporarily install the manifold stay to the transmission assembly and exhaust manifold assembly RH with the 3 bolts.


b.
A441048C02
0.125,0.073 0.438,0.229 0.313,0.156 10 true *A 0.115,2.479 0.427,2.635 0.313,0.156 10 true *B 0.667,4.073 0.844,4.271 0.177,0.198 10 true 1 1.01,1.948 1.167,2.146 0.156,0.198 10 true 1 2.219,3.021 2.375,3.219 0.156,0.198 10 true 2 2.448,0.823 2.604,1.021 0.156,0.198 10 true 2 2.323,0.313 2.479,0.51 0.156,0.198 10 true 3 2.031,2.448 2.188,2.646 0.156,0.198 10 true 3
*A w/ Secondary Air Injection System
*B w/o Secondary Air Injection System


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

Torque:
40 N*m (408 kgf*cm, 30 ft.*lbf)


Hide 17450B 11.INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY

a.
A128853

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

Minimum free length:

40.5 mm (1.59 in.)


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


b.
A076194C47
2.031,1.583 1.594,1.885 1.594,1.885 1.479,1.885 true 2.438,0.979 3.042,0.979 true 1.271,1.781 1.49,1.958 0.219,0.177 10 false *1 3.104,0.875 3.323,1.052 0.219,0.177 10 false *a
*1 Gasket
*a Wooden Block


Using a plastic-faced hammer and wooden block, tap in a new gasket until its surface is flush with the front exhaust pipe assembly.

NOTICE:
·

Be sure to install the gasket so that it faces the correct direction.

·

Do not reuse the gasket.

·

Do not damage the gasket.

·

When connecting the center exhaust pipe assembly, do not push in the gasket with the center exhaust pipe assembly.




c.

Install the 2 new gaskets to the front No. 2 exhaust pipe assembly.


d.

Install the front No. 2 exhaust pipe assembly with the 2 bolts, 2 compression springs and 2 new nuts.

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


e.

Connect the heated oxygen sensor connector and wire harness clamp.


Hide 17410 12.INSTALL FRONT EXHAUST PIPE ASSEMBLY

a.

Install the 2 new gasket to the front exhaust pipe assembly.


b.

Install the front exhaust pipe assembly with the 2 bolts and 2 new nuts.

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


c.

w/ Secondary Air Injection System:

Connect the heated oxygen sensor connector.


d.

w/o Secondary Air Injection System:

Connect the heated oxygen sensor connector and wire harness clamp.


Hide 14.INSPECT FOR EXHAUST GAS LEAK

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