EXHAUST MANIFOLD INSTALLATION

PROCEDURE

1. INSTALL NO. 2 MANIFOLD CONVERTER INSULATOR (for AWD)

   
   

   1. Exhaust manifold assembly LH side:

      
      

      1. Install the No. 2 manifold converter insulator to the exhaust manifold assembly with the 3 bolts.

         Torque:

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

   2. Exhaust manifold assembly RH side:

      
      

      1. Install the No. 2 manifold converter insulator to the exhaust manifold assembly with the 4 bolts.

         Torque:

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

2. INSTALL NO. 2 MANIFOLD CONVERTER INSULATOR (for 2WD)

   
   

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

      Torque:

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

3. INSTALL NO. 1 MANIFOLD CONVERTER INSULATOR (for AWD)

   
   

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

      Torque:

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

4. INSTALL NO. 1 MANIFOLD CONVERTER INSULATOR (for 2WD)

   
   

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

      Torque:

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

5. 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 }

6. INSTALL EXHAUST MANIFOLD ASSEMBLY RH (for AWD)

   Tech Tips

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

   
   

   • w/ Canister Pump Module:

     Click here

   • w/o Canister Pump Module:

     Click here

   
   

   1. 

      *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.

   4. 

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

      Torque:

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

7. INSTALL EXHAUST MANIFOLD ASSEMBLY RH (for 2WD)

   Tech Tips

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

   
   

   • w/ Canister Pump Module:

     Click here

   • w/o Canister Pump Module:

     Click here

   
   

   1. 

      *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.

   4. 

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

      Torque:

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

8. INSTALL EXHAUST MANIFOLD ASSEMBLY LH (for AWD)

   Tech Tips

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

   
   

   • w/ Canister Pump Module:

     Click here

   • w/o Canister Pump Module:

     Click here

   
   

   1. 

      *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.

   4. 

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

      Torque:

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

9. INSTALL EXHAUST MANIFOLD ASSEMBLY LH (for 2WD)

   Tech Tips

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

   
   

   • w/ Canister Pump Module:

     Click here

   • w/o Canister Pump Module:

     Click here

   
   

   1. 

      *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. 

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

10. TEMPORARILY INSTALL FRONT PROPELLER SHAFT ASSEMBLY (for AWD)

11. TIGHTEN FRONT PROPELLER SHAFT ASSEMBLY (for AWD)

12. 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.

13. INSTALL NO. 1 EGR PIPE

    Click here

14. INSTALL FENDER APRON BRACE SUB-ASSEMBLY RH

    Click here

15. CONNECT GENERATOR CABLE AND MOTOR CABLE

    Click here

16. INSTALL REAR LOWER ARM MOUNTING REINFORCEMENT SUB-ASSEMBLY RH (for 2WD)

    
    

    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 }

17. INSTALL ENGINE SIDE COVER RH (for 2WD)

    
    

    1. Attach the clamp, 4 clips and install the engine side cover RH.

18. 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 }

19. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

20. INSTALL FRONT CENTER FLOOR BRACE SUB-ASSEMBLY

    Click here

21. INSTALL FLOOR BOARD SUB-ASSEMBLY

    Click here

22. INSTALL NO. 2 FLOOR BOARD SUB-ASSEMBLY

    Click here

23. INSTALL REAR FLOOR SIDE MEMBER COVER RH

    Click here

24. INSTALL REAR FLOOR SIDE MEMBER COVER LH

    Click here

25. INSTALL STRUT BAR BRACKET SUPPORT SUB-ASSEMBLY (for AWD)

    Click here

26. INSTALL FRONT SUSPENSION MEMBER BRACE (for AWD)

    Click here

27. INSTALL NO. 2 ENGINE UNDER COVER ASSEMBLY (for AWD)

    Click here

28. INSTALL TRANSMISSION UNDER COVER (for AWD)

    Click here

29. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY (for AWD)

    Click here

30. INSTALL STRUT BAR BRACKET SUPPORT SUB-ASSEMBLY (for 2WD)

    Click here

31. INSTALL FRONT SUSPENSION MEMBER BRACE (for 2WD)

    Click here

32. INSTALL NO. 2 ENGINE UNDER COVER ASSEMBLY (for 2WD)

    Click here

33. INSTALL TRANSMISSION UNDER COVER (for 2WD)

    Click here

34. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY (for 2WD)

    Click here

35. 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 }

36. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE (for AWD)

    Click here

37. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE (for 2WD)

    
    

    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.

38. INSTALL AIR CLEANER WITH AIR CLEANER HOSE

    Click here

39. INSTALL NO. 1 AIR CLEANER INLET

    Click here

40. INSTALL RADIATOR SUPPORT TO CROSSMEMBER BRACE SUB-ASSEMBLY RH

    
    

    1. Install the radiator support to cross member brace sub-assembly RH with the 2 bolts.

       Torque:

       49 N*m  { 500 kgf*cm, 36 ft.*lbf }

41. INSTALL RADIATOR SUPPORT TO CROSSMEMBER BRACE SUB-ASSEMBLY LH

    
    

    1. Install the radiator support to cross member brace sub-assembly LH with the 2 bolts.

       Torque:

       49 N*m  { 500 kgf*cm, 36 ft.*lbf }

42. INSTALL LOWER RADIATOR AIR DEFLECTOR

    
    

    1. Attach the 7 clips to install the lower radiator air deflector.

43. INSTALL UPPER RADIATOR SUPPORT SEAL

    
    

    1. Attach the 7 clips to install the upper radiator support seal.

44. INSTALL RADIATOR COVER PLATE

    
    

    1. Attach the 7 clips to install the radiator cover plate.

45. INSTALL V-BANK COVER SUB-ASSEMBLY

    Click here

46. INSPECT FOR EXHAUST GAS LEAK

    Click here