90103-ZW4-H01 Honda BOLT (M8X50) (Honda Code 7759293).

Introduction
The correct installation of emissions critical components is vital to comply with the relevant emissions legislation. In addition, it is important to highlight the key assembly characteristics of other components that are transported loose. The assembly of the loose components is carried out by a representative of the customer.This Special Instruction is intended to be used in addition to the Service Manual. This document should be used as an assembly guide or a reference document when developing processes for production assembly facilities. Critical assembly characteristics such as tightening torques, component orientation, and assembly sequences must be followed to achieve the required product quality and emissions regulations.The Service Manual consists of the following manuals.
Operation and Maintenance Manual
Disassembly and Assembly
Troubleshooting
Systems Operation Testing and Adjusting
SpecificationsCustomers are permitted to paint the engine as received or as part of a power train sub assembly. These engines are supplied in gray primer.The customer is not permitted to paint the aftertreatment or exhaust systems, turbocharger, Electronic Control Module (ECM), starting motor, alternator, or belts. The customer is also not permitted to paint any filters and filter canisters. The canisters include fuel, air, oil, or crankcase breather.The customer is required to develop suitable plugs and masks to a standard equivalent to that used in the engine assembly plant.The customer is required to prevent water ingress into the engine by maintaining a standard of plugging equivalent to that used in the engine assembly plant.Safety Section
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Engine Air Cleaner and Air Inlet Temperature sensor
Illustration 1 g06529582
Typical example
(1) Air Cleaner
(2) Air Inlet Temperature Sensor
(3) O-ring Seal
(4) Hose Clamp
(5) Inlet Elbow
(6) Hose ClampThe engine air cleaner (1) can be supplied as a loose assembly. The engine air cleaner should be mounted horizontally. The dust exhaust port must be at the lowest point and positioned in a direction that is down.Note: Do not paint the dust exhaust port. Solvents and chemicals will shorten the usable life of the exhaust portNote: There are several variations of engine air cleanerStandard duty air cleanerTighten the M8 nuts to the following torque. ... 22 N m (195 lb in)Tighten the hose clamps to the following torque. ... 3.5 N m (31 lb in)Tighten the air inlet temperature sensor to the following torque. ... 20 N m (177 lb in)Flexible Exhaust Pipe
The flexible exhaust pipe is a series of separate components that connect the exhaust elbow outlet to the inlet of the Clean Emissions Module (CEM). The flexible exhaust pipe has been designed to account for some lateral or axial misalignment due to component tolerances.The bellows are supplied with a protective sleeve. The protective sleeve protects the bellows from damage when the bellows is transported and installed.Note: Do not remove the protective sleeve until the installation of the flexible exhaust pipe is complete.It is possible to disturb the bellows from the neutral position. It is critical not to disrupt the bellows from the neutral position when the bellows is installed. All component tolerances must be absorbed by the clamps and the ball clamps.Note: Ensure that the assembly of the flexible exhaust pipe is supported always.
Illustration 2 g06516366
Typical example
Note: Ensure that the bellows are not subjected to any undue stress.
Position new flare (4) and new seal (5) onto exhaust tube (3).Note: Ensure correct orientation of the new seal and the new flare.Note: Exhaust tube (3) is supplied by the Original Engine Manufacturer (OEM)
Position exhaust tube (3) in a suitable support. Install bellows (1) onto the exhaust tube in Position (X). Support bellows and install clamp (6) and nut (7). Hand tighten the nut.
Illustration 3 g06516290
Typical example
Note: Ensure that the bellows are not subjected to any undue stress.
Position new flare (9) and new seal (10) onto exhaust adaptor (8). Position new flare (9) and new seal (10) onto exhaust tube (3).Note: Ensure correct orientation of the new seal and the new flare.Note: Ensure that the bellows are not subjected to any undue stress.
Position the flexible tube assembly (2) between exhaust adaptor (8) and remotely mounted Clean Emissions Module (CEM) (13). Support the tube assembly and install clamp (11) and nut (12) in Position (Y). Hand tighten the clamp.
Install clamp (11) and nut (12) in Position (Z). Hand tighten the clamp.
Tighten nut (12) in Position (Y) to a torque of 8 N m (71 lb in).
Tighten nut (12) in Position (Z) to a torque of 8 N m (71 lb in).
Tighten nut (7) to a torque of 8 N m (71 lb in).
Remove the bellows protective sleeve using a suitable tool.Installation of the Remote Mounted Aftertreatment
Wear goggles, gloves, protective clothing, and a National Institute for Occupational Safety and Health (NIOSH) approved P95 or N95 half-face respirator when handling a used Diesel Particulate Filter or Catalytic Converter Muffler. Failure to do so could result in personal injury.
Care must be taken when the Clean Emissions Module (CEM) is removed from the transportation crate.
After the Clean Emissions Module (CEM) is removed from the transportation crate, the CEM should be inspected. Inspect the CEM for damage.Use a suitable lifting device to lift the CEM.Installation of Remote Horizontally Mounted Aftertreatment