EXHAUST GAS TEMPERATURE SENSOR(for Lower Side) INSTALLATION

PROCEDURE


  1. INSTALL NO. 2 EXHAUST GAS TEMPERATURE SENSOR


    1. B0045JDE01
      Text in Illustration
      *a Union Nut Wrench Fulcrum Length
      *b Torque Wrench Fulcrum Length

      Using a union nut wrench 14 mm, install the No. 2 exhaust gas temperature sensor to the exhaust manifold.

      Torque:
      Specified tightening torque
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

      Tech Tips


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

      • When a union nut wrench 14 mm (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 26 N*m (265 kgf*cm, 19 ft.*lbf)

  2. INSTALL AIR FUEL RATIO SENSOR (for Sensor 2)

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  3. INSTALL NO. 1 PIPE


    1. Temporarily install the No. 1 pipe to the exhaust manifold.

    2. Connect the No. 1 pipe to the exhaust manifold with the bolt.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    3. B0045E6

      Tighten the No. 1 pipe.

      Torque:
      Specified tightening torque
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }

      Tech Tips


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

      • When a union nut wrench 14 mm (fulcrum length of 25 mm (0.98 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 42 N*m (428 kgf*cm, 31 ft.*lbf)

  4. INSTALL EXHAUST MANIFOLD


    1. Install a new gasket to the turbocharger sub-assembly.

    2. B0047YG

      As shown in the illustration, fix the exhaust manifold to the vehicle using a rope or similar.

      Note

      Make sure to perform this step in order to prevent the exhaust manifold from falling.

    3. B0045XLE02
      Text in Illustration
      *a Torque Wrench Fulcrum Length
      *b Offset Wrench Fulcrum Length

      Temporarily install the No. 1 converter support bracket to the cylinder block sub-assembly with the 3 bolts.

    4. Using a 12 x 14 mm offset wrench and a 12 mm hexagon socket wrench, fully tighten the bolt A.

      Torque:
      Specified tightening torque
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

      Tech Tips


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

      • When using a 12 x 14 mm offset wrench and a 12 mm hexagon socket wrench (fulcrum length of 206 mm (8.11 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 17 N*m (173 kgf*cm, 13 ft.*lbf)

    5. Fully tighten the 2 bolts B.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

    6. Temporarily install the exhaust manifold to the turbocharger sub-assembly, No. 1 converter support bracket, manifold stay and No. 2 converter support bracket with the 4 bolts and 3 new nuts.

      B0046LVE01

    7. Fully tighten the 4 bolts and 3 nuts, in the sequence shown in the illustration.

      Torque:
      Bolt
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }
      Nut
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }

  5. INSTALL DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY


    1. Install the drive shaft heat insulator sub-assembly to the No. 1 converter support bracket with the 2 nuts.

      Torque:
      18 N*m  { 179 kgf*cm, 13 ft.*lbf }

  6. INSTALL NO. 4 CONVERTER SUPPORT BRACKET


    1. B0047Y3E01

      Install the No. 4 converter support bracket to the exhaust manifold and No. 1 converter support bracket with the 3 bolts, in the sequence shown in the illustration.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  7. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

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  8. INSTALL NO. 5 CONVERTER SUPPORT BRACKET


    1. B0045MJE01

      Install the No. 5 converter support bracket to the exhaust manifold and cylinder block sub-assembly with the 2 bolts, in the sequence shown in the illustration.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  9. INSTALL NO. 2 PIPE


    1. B004888

      Temporarily install the No. 2 pipe to the exhaust manifold.

    2. Connect the No. 2 pipe to the manifold stay with the bolt.

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

    3. Tighten the No. 2 pipe.

      Torque:
      Specified tightening torque
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

      Tech Tips


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

      • When a union nut wrench 14 mm (fulcrum length of 25 mm (0.98 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 26 N*m (265 kgf*cm, 19 ft.*lbf)

    4. Engage the 2 clamps to connect the air fuel ratio sensor wire to the No. 2 pipe.

    5. Engage the clamp to connect the No. 2 exhaust gas temperature sensor wire to the No. 2 pipe.

  10. INSTALL TURBO INSULATOR


    1. Install the turbo insulator to the turbocharger sub-assembly and exhaust manifold with the 3 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    2. Engage the 2 clamps to connect the air fuel ratio sensor wire and No. 2 exhaust gas temperature sensor wire to the turbo insulator.

  11. INSTALL EXHAUST GAS TEMPERATURE SENSOR

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  12. INSTALL AIR FUEL RATIO SENSOR (for Sensor 1)

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  13. INSTALL SENSOR BRACKET


    1. Install the sensor bracket to the cylinder head cover sub-assembly with the 2 bolts.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  14. INSTALL NO. 2 ENGINE COVER BRACKET


    1. Install the No. 2 engine cover bracket to the sensor bracket and wiring harness clamp bracket with the bolt and 2 nuts.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  15. INSTALL NO. 1 AIR TUBE

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  16. INSTALL NO. 2 AIR HOSE

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  17. INSTALL BATTERY CARRIER (for LHD)

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  18. INSTALL BATTERY CARRIER (for RHD)

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  19. INSTALL BATTERY TRAY

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  20. INSTALL BATTERY

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  21. CONNECT NO. 1 HOSE TO HOSE TUBE (for LHD)


    1. Connect the No. 2 hose to hose tube to the vehicle with the bolt.

      Torque:
      8.3 N*m  { 85 kgf*cm, 73 in.*lbf }

  22. CONNECT NO. 2 HOSE TO HOSE TUBE (for RHD)


    1. Connect the No. 1 hose to hose tube to the vehicle with the 2 bolts.

      Torque:
      8.3 N*m  { 85 kgf*cm, 73 in.*lbf }

    2. Connect the connector to check valve hose to the No. 1 hose to hose tube and slide the hose clip to secure it.

  23. INSTALL DIFFERENTIAL PRESSURE SENSOR ASSEMBLY

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  24. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. B0048A3

      Using a vernier caliper, measure the free length of the compression spring.

      Minimum length
      41.5 mm (1.633 in.)

      If the length is not as specified, replace the compression spring.

    2. B0047W0E06
      Text in Illustration
      *1 Gasket
      *2 Wooden Block

      Using a plastic hammer and a wooden block, tap in a new exhaust pipe gasket until its surface is flush with the exhaust manifold.

      Note


      • Install the exhaust pipe gasket in the correct direction.

      • Do not damage the outer surface of the exhaust pipe gasket.

      • Do not reuse the exhaust pipe gasket.

      • Do not push in the gasket with the exhaust pipe when connecting it.

    3. Hang the front exhaust pipe assembly with the 3 exhaust pipe supports.

    4. Install the new No. 2 exhaust pipe gasket onto the front exhaust pipe assembly.

    5. Install the front exhaust pipe assembly to the tail exhaust pipe assembly with the 2 bolts.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

      Note

      Do not reuse the removed gasket.

    6. Install the front exhaust pipe assembly with the 2 compression springs and 2 bolts.

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

  25. INSTALL FRONT FLOOR CENTER BRACE

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  26. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

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  27. CONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  28. INSPECT FOR EXHAUST GAS LEAK

  29. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

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