Exhaust Gasket - Front

This procedure covers replacement of the front exhaust gasket (turbocharger to downpipe/catalytic converter connection) on the 1.5L turbo engine.

Warnings

Tools required

Parts

• Front exhaust gasket (turbo to downpipe) × 1 — Use OEM Honda gasket
• Exhaust flange nuts or bolts (if damaged) × 3 — Use OEM specification
• Anti-seize compound × 1 — High-temperature rated

Preparation

1. Ensure engine is completely cold to the touch (minimum 2 hours after last operation)
2. Park vehicle on level surface and engage parking brake
3. Raise front of vehicle and support securely on jack stands
4. Remove plastic engine undercover using 10mm socket
5. Spray all exhaust flange fasteners with penetrating oil and allow 15-20 minutes to soak

Procedure

1. 1

   Remove heat shield (if equipped)
   Locate the heat shield covering the turbocharger and front exhaust connection. Remove the heat shield bolts using a 10mm socket. Set heat shield aside for reinstallation.
   Torque spec

   Heat Shield Bolts10 Nm (7 lb-ft)
2. 2

   Disconnect oxygen sensor connector (if applicable)
   If the primary oxygen sensor is mounted near the front exhaust flange, disconnect the electrical connector by pressing the release tab. Carefully move the wiring harness out of the work area. Do not disconnect the sensor itself unless necessary for clearance.
   ⚠Oxygen sensor connectors are fragile. Do not force the connector or pull on the wiring.
3. 3

   Support the exhaust system
   Place a support (jack stand or block) under the catalytic converter/downpipe to prevent excessive weight on the connection during disassembly. The exhaust should be supported but not under tension.
   ⚠Do not allow the exhaust system to hang unsupported, as this can damage hangers or the turbocharger outlet.
4. 4

   Remove front exhaust flange fasteners
   Locate the three bolts or nuts connecting the turbocharger outlet to the front exhaust pipe/catalytic converter. Using a 14mm socket with extensions, remove all three fasteners. Work evenly across the flange to prevent binding. If fasteners are severely corroded, apply additional penetrating oil and carefully work them loose.
   ⚠Seized fasteners may break if excessive force is applied. If a fastener begins to strip or twist, stop and apply heat or additional penetrating oil.
5. 5

   Separate exhaust flange and remove old gasket
   Carefully pull the exhaust pipe away from the turbocharger outlet flange. The gasket may be stuck to either surface. Use a flathead screwdriver to gently pry if necessary. Remove and discard the old gasket. Inspect both mating surfaces for damage or warping.
   ℹ️Some exhaust movement may be required. Do not force or bend the exhaust pipe excessively.
6. 6

   Clean mating surfaces
   Use a wire brush or scraper to thoroughly clean both the turbocharger outlet flange and the exhaust pipe flange. Remove all old gasket material, carbon deposits, and corrosion. Both surfaces must be completely clean and flat for proper sealing.
   ⚠Avoid gouging or scratching the mating surfaces. Deep scratches can prevent proper sealing.
7. 7

   Install new exhaust gasket
   Position the new exhaust gasket on the turbocharger outlet flange. Ensure the gasket is properly oriented and aligned with all bolt holes. The gasket should sit flat without gaps or misalignment.
   ℹ️Some gaskets have a specific orientation with a TOP marking. Verify correct installation direction.
8. 8

   Reconnect exhaust flange
   Carefully guide the exhaust pipe back to the turbocharger outlet, aligning the flange with the new gasket. Insert all three bolts or studs through the flange. Thread the nuts or bolts by hand to ensure proper alignment before tightening.
   ⚠Ensure the gasket remains properly positioned and does not shift during alignment.
9. 9

   Apply anti-seize and torque flange fasteners
   Apply a thin coat of high-temperature anti-seize compound to the threads of the exhaust flange bolts. Using a torque wrench, tighten the three fasteners in a crisscross pattern to 45.0 Nm (33.0 lb-ft). Make multiple passes, gradually increasing torque to ensure even loading.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
10. 10

    Remove exhaust support and reconnect sensor
    Remove the temporary support from under the exhaust system. If the oxygen sensor connector was disconnected, reconnect it firmly until the release tab clicks into place. Verify the wiring is routed properly and not touching hot exhaust components.
    ⚠Ensure oxygen sensor wiring has adequate clearance from exhaust components to prevent heat damage.
11. 11

    Reinstall heat shield
    Position the heat shield back over the turbocharger and exhaust connection. Install and tighten the heat shield bolts to 10.0 Nm (7.0 lb-ft) using a torque wrench.
    Torque spec

    Heat Shield Bolts10 Nm (7 lb-ft)

Reassembly

1. Reinstall plastic engine undercover using 10mm bolts
2. Lower vehicle from jack stands
3. Verify all tools and parts have been removed from engine bay

Verification

• Start the engine and allow it to idle for 2-3 minutes
• Listen for exhaust leaks at the front flange connection (hissing or ticking sounds)
• Visually inspect the connection area for signs of exhaust gas leakage
• Rev the engine gently to 2000-3000 RPM and recheck for leaks
• Check for any illuminated check engine lights related to oxygen sensor or exhaust system
• After a short test drive, allow engine to cool slightly and re-inspect the connection for any signs of leakage or looseness

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