40159-ZW5-000 Honda SEAL, SEPARATOR CASE (Honda Code 5892500).

Sulfuric Acid Burn Hazard may cause serious personal injury or death.The exhaust gas cooler may contain a small amount of sulfuric acid. The use of fuel with sulfur levels greater than 15 ppm may increase the amount of sulfuric acid formed. The sulfuric acid may spill from the cooler during service of the engine. The sulfuric acid will burn the eyes, skin and clothing on contact. Always wear the appropriate personal protective equipment (PPE) that is noted on a material safety data sheet (MSDS) for sulfuric acid. Always follow the directions for first aid that are noted on a material safety data sheet (MSDS) for sulfuric acid.
Ensure that wiring harness are correctly routed and the cable straps are not over tightened. Over tightening of the cable straps will damage the wiring harness convoluting.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged.
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If necessary, follow Step 2a through Step 2d to install bracket (28).
Position bracket (28) onto cylinder head (29).
Install bolts (27) hand tight. Ensure that rubber sleeve (31) is correctly positioned into recess of bracket (28).
Tighten bolts (27) to a torque of 22 N m (195 lb in).
Install new cable straps (30).Note: Ensure that the cable straps meet the Original Equipment Manufacture (OEM) specification.
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Position a new gasket (17) onto inlet air control assembly (8). Ensure gasket (17) is correctly installed into locating Pins (X).
Loosen bolts (33) for bracket (32).
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Position inlet air control assembly (8) onto the bracket.Note: Ensure that the inlet air control assembly is correctly installed onto the hose assembly for the inlet elbow.
Install bolts (26) to inlet air control assembly (8) hand tight.
Install bolts (14) hand tight. Ensure that the gasket (17) remains correctly positioned onto inlet air control assembly (8).
Tighten bolts (26) to a torque of 22 N m (195 lb in).
Tighten bolts (14) to a torque of 22 N m (195 lb in).
Tighten bolts (33) for bracket (32) to a torque of 44 N m (32 lb ft).
Position tube assembly (25) onto inlet air control assembly (8). Loosely install bolt (24) and bolt (15) to the tube assembly.
Install sealing washer (22) (not shown) to banjo bolt (23). Install the banjo bolt to tube assembly (25) and install remaining sealing washer (22) (not shown) to the banjo bolt.
Tighten banjo bolt (23) to a torque of 15 N m (133 lb in).
Tighten bolt (24) and bolt (15) to a torque of 22 N m (195 lb in).
Position a new hose clamp (18) onto hose assembly (19). Install hose assembly to inlet air control assembly (8). Tighten hose clamp (18).
Position a new hose clamp (20) onto hose assembly (21). Install hose assembly to inlet air control assembly (8). Tighten hose clamp (20).
Install temperature sensor (16) to the inlet air control assembly. Refer to Disassembly and Assembly, "Temperature Sensor (Cooled Exhaust Gas) - Remove and Install" for the correct procedure.
Connect hose assembly (13) to the wastegate actuator. Slide clip (12) along hose assembly (13). Ensure that the clip is correctly positioned onto the hose.
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Illustration 8 g02518536
Hose clamp Type (A)
Hose clamp Type (B)
Tighten hose clamps (10) on the hose assembly that connects inlet air control assembly (8) to inlet elbow (11). Refer to Illustration 8 to determine the correct type of hose clamp.Tighten hose clamps Type (A) to a torque of 11 N m (97 lb in).Tighten hose clamps Type (B) to a torque of 7 N m (62 lb in).
Slide connection for wiring harness assembly (4) onto bracket (3). Connect engine wiring harness assembly (2) to wiring harness assembly (4) for wastegate solenoid (6).
Slide the connection for wiring harness assembly (5) onto bracket (3). Connect engine wiring harness assembly (1) to wiring harness assembly (5) for NRS valve (7).
Connect the hose assembly to connection (9) for inlet air control (8). Tighten the hose clamps to a torque of 6 N m (53 lb in).
Install new cable straps to the engine wiring harness assemblie