Repair Procedures

Removal

1. Disconnect the negative terminal from the battery.
2. Remove the engine room cover (A).




3. Remove the air duct (A), and the air cleaner assembly (B).




4. Remove the oil level gauge (A).




5. Disconnect the oxygen sensor (HO2S) connector (A) and remove the wiring bracket (B).








6. Remove the exhaust manifold stay (A) and then disconnect the front muffler (B) on LH and RH side.




7. Remove the exhaust manifold heat protector (A).

[RH]





[LH]





NOTE:
To remove the exhaust manifold and heat protector on LH side, remove the cylinder head cover on LH side first. Be careful not to put any harmful materials in the cylinder head during work.




8. Remove the exhaust manifold (A).

[RH]





NOTE:
Use an universal joint wrench (B) to loosen the upper and lower nuts on the RH exhaust manifold.

[LH]





NOTE:
Use an universal joint wrench (B) to loosen the upper nuts on the LH exhaust manifold. To loosen the lower nuts on the LH exhaust manifold, use an extension bar (C) and an universal joint (D) after removing the front wheel and side cover on LH side.





Installation

1. Install the exhaust manifold (A).

Tightening torque :
49.0 - 53.9N.m (5.0 - 5.5kgf.m, 36.2 - 39.8lb-ft)

NOTE:
The "TOP" mark of the gasket must be face the exhaust manifold.

[RH]





[LH]





NOTE:
Tighten the exhaust manifold mounting nuts as following method.

[RH]





[LH] - With engine assembly removal





[LH] - Without engine assembly removal




2. Install the exhaust manifold heat protector (A).

Tightening torque :
8.8 - 10.8N.m ( 0.9 - 1.1kgf.m, 6.5 - 8.0lb-ft)

[RH]





[LH]





NOTE:
After installing the exhaust manifold and heat protector on LH side, install the cylinder head.

3. Install the exhaust manifold stay (A) and reconnect the front muffler (B) on LH and RH side.

Tightening torque
Bolts (C):
34.3 - 41.2N.m ( 3.5 - 4.2kgf.m, 25.3 - 30.4lb-ft)
Nuts (D):
49.0 - 53.9N.m ( 5.0 - 5.5kgf.m, 36.2 - 39.8lb-ft)




4. Reconnect the oxygen sensor (HO2S) connector (A) and install the wiring connector bracket (B).








5. Install the oil level gauge (A).

Tightening torque :
9.8 - 11.8Nm (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)




6. Install the air cleaner assembly (B) and air duct (A).

Tightening torque
Hose clamp bolt:
2.9 - 4.9N.m (0.3 - 0.5kgf.m, 2.2 - 3.6lb-ft)
Air cleaner assembly bolts:
7.8 - 9.8N.m (0.8 - 1.0kgf.m, 5.8 - 7.2lb-ft)




7. Install the engine room cover (A).




8. Reconnect the battery negative terminal.

Tightening torque :
4.0 - 6.0N.m (0.4 - 0.6kgf.m, 3.0 - 4.4lb-ft)