EXHAUST MANIFOLD INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips

Perform "Inspection After Repairs" after replacing the air fuel ratio sensor.


PROCEDURE


  1. INSTALL NO. 2 MANIFOLD CONVERTER INSULATOR


    1. Install the 2 No. 2 manifold converter insulators to the exhasut manifold assembly with the 8 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  2. INSTALL NO. 1 MANIFOLD CONVERTER INSULATOR


    1. Install the 2 No. 1 manifold converter insulators to the exhasut manifold assembly with the 8 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  3. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the 2 No. 1 exhaust manifold heat insulators to the exhaust manifold assembly with the 6 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  4. INSTALL EXHAUST MANIFOLD ASSEMBLY RH

    Tech Tips

    Perform "Inspection After Repairs" after replacing the air fuel ratio sensor.



    1. B004C1VC01
      *A Bank 1 Sensor 1 Side
      *B Bank 1 Sensor 2 Side
      *a Torque Wrench Fulcrum Length

      Using SST, install the air fuel ratio sensor to the exhaust manifold assembly RH.

      SST
      09224-00012
      Torque
      Specified tightening torque
      44 N*m (449 kgf*cm, 32 ft.*lbf)

      Note

      Replace with a new part if it is dropped or if it receives a strong impact.

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Click here

      • When using SST (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 37.7 N*m (384 kgf*cm, 28 ft.*lbf)

    2. Install a new gasket to the cylinder head sub-assembly.

    3. Temporarily install the exhaust manifold assembly RH with 4 new nuts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    4. B004BU6N01

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

  5. INSTALL EXHAUST MANIFOLD ASSEMBLY LH

    Tech Tips

    Perform "Inspection After Repairs" after replacing the air fuel ratio sensor.



    1. B0049Y4C01
      *A Bank 2 Sensor 1 Side
      *B Bank 2 Sensor 2 Side
      *a Torque Wrench Fulcrum Length

      Using SST, install the air fuel ratio sensor to the exhaust manifold assembly LH.

      SST
      09224-00012
      Torque
      Specified tightening torque
      44 N*m (449 kgf*cm, 32 ft.*lbf)

      Note

      Replace with a new part if it is dropped or if it receives a strong impact.

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Click here

      • When using SST (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 37.7 N*m (384 kgf*cm, 28 ft.*lbf)

    2. Install a new gasket to the cylinder head sub-assembly LH.

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

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    4. B004BWLN01

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

  6. CONNECT AIR FUEL RATIO SENSOR


    1. for Bank 1 Sensor 1:


      1. Connect the connector.

      2. Attach the 3 wire harness clamps.

    2. for Bank 1 Sensor 2:


      1. Connect the connector.

      2. Attach the 2 wire harness clamps.

    3. for Bank 2 Sensor 1:


      1. Connect the connector.

      2. Attach the 4 wire harness clamps.

    4. for Bank 2 Sensor 2:


      1. Connect the connector.

      2. Attach the 3 wire harness clamps.

  7. INSTALL NO. 1 EGR PIPE

    Click here

  8. INSTALL FENDER APRON BRACE SUB-ASSEMBLY RH

    Click here

  9. INSTALL INVERTER MOTOR CABLE BRACKET ASSEMBLY (for LHD)

    Click here

  10. CONNECT GENERATOR CABLE AND MOTOR CABLE (for LHD)

    Click here

  11. INSTALL REAR LOWER ARM MOUNTING REINFORCEMENT SUB-ASSEMBLY RH


    1. Install the rear lower arm mounting reinforcement sub-assembly RH with the 4 bolts.

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

  12. INSTALL ENGINE SIDE COVER RH


    1. Attach the 4 clips to install the engine side cover RH.

  13. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY


    1. Install the No. 1 exhaust pipe support bracket sub-assembly with the 2 bolts.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  14. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  15. INSTALL FRONT FLOOR BRACE SUB-ASSEMBLY CENTER

    Click here

  16. INSTALL FRONT FLOOR COVER RH

    Click here

  17. INSTALL FRONT FLOOR COVER LH

    Click here

  18. INSTALL FRONT FENDER SEAL RH

    Click here

  19. INSTALL FRONT FENDER SEAL LH

    Click here

  20. INSTALL REAR FLOOR SIDE MEMBER COVER RH

    Click here

  21. INSTALL REAR FLOOR SIDE MEMBER COVER LH

    Click here

  22. INSTALL NO. 2 ENGINE UNDER COVER ASSEMBLY

    Click here

  23. INSTALL FRONT APRON FENDER INSULATOR LH


    1. Install the front fender apron insulator LH with the 3 bolts.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  24. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Install a new O-ring to the No. 2 engine oil level dipstick guide.

    2. Install the No. 2 engine oil level dipstick guide with the bolt.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    3. Install the engine oil level dipstick to the No. 2 engine oil level dipstick guide.

  25. INSTALL AIR CLEANER WITH AIR CLEANER HOSE

    Click here

  26. INSTALL NO. 1 AIR CLEANER INLET

    Click here

  27. INSTALL RADIATOR SUPPORT TO CROSS MEMBER BRACE SUB-ASSEMBLY RH

    Click here

  28. INSTALL LOWER RADIATOR AIR DEFLECTOR


    1. Attach the 9 clips to install the lower radiator air deflector.

  29. INSTALL RADIATOR SUPPORT TO FRAME SEAL RH


    1. Attach the 6 clips to install the radiator support to frame seal RH.

  30. INSTALL V-BANK COVER SUB-ASSEMBLY

    Click here

  31. INSPECT FOR EXHAUST GAS LEAK

    Click here