EXHAUST MANIFOLD INSTALLATION


  1. INSTALL HEATED OXYGEN SENSOR (for Bank 2 Sensor 1)

    A01GMK4E02

    1. Using SST, remove the heated oxygen sensor from the exhaust manifold RH.

      SST
      09224-00010
      Torque:
      without SST
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }
      with SST
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

      Tech Tips


      • Use a torque wrench with a fulcrum length of 300 mm (11.8 in.). When using a torque wrench with a fulcrum length that is not 300 mm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification Click here.

      • Make sure SST and the wrench are connected in a straight line.

  2. INSTALL HEATED OXYGEN SENSOR (for Bank 1 Sensor 1)

    A01GJ6LE01

    1. Using SST, remove the heated oxygen sensor from the exhaust manifold LH.

      SST
      09224-00010
      Torque:
      without SST
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }
      with SST
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

      Tech Tips


      • Use a torque wrench with a fulcrum length of 300 mm (11.8 in.). When using a torque wrench with a fulcrum length that is not 300 mm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification Click here.

      • Make sure SST and the wrench are connected in a straight line.

  3. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH


    1. A01GHPR

      Install a new gasket as shown in the illustration.

      Text in Illustration
      A01GKOV Front
    2. A01GLYYE02

      Install the exhaust manifold to the cylinder head with the new 8 nuts in the order shown in the illustration.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Text in Illustration
      A01GNZA Front

  4. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01GNSZ

      Install the heat insulator with the 3 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. A01GNRH

      Connect the sensor connector.

  5. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH


    1. A01GJ5E

      Install a new gasket as shown in the illustration.

      Text in Illustration
      A01GKOV Front
    2. A01GL4QE02

      Install the exhaust manifold to the cylinder head with the new 8 nuts in the order shown in the illustration.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Text in Illustration
      A01GNZA Front

  6. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01GLJH

      Install the heat insulator with the 3 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. A01GIOR

      Connect the sensor connector.

  7. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Apply a light coat of engine oil to a new O-ring.

    2. Install the new O-ring to the engine oil level dipstick guide.

    3. Install the engine oil level dipstick guide with the 2 bolts.

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

    4. Install the engine oil level dipstick.

  8. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (w/ VGRS)


    1. Install the clamp to the steering column hole cover sub-assembly.

    2. A01GLV7E02
      Text in Illustration
      *a Matchmark

      Align the matchmarks on the No. 2 steering intermediate shaft assembly and steering column.

    3. Install the bolt.

      Torque:
      35 N*m  { 360 kgf*cm, 26 ft.*lbf }
    4. A01GKUZE02
      Text in Illustration
      *a Matchmark

      Align the matchmarks on the No. 2 steering intermediate shaft assembly and power steering link.

    5. Install the bolt.

      Torque:
      35 N*m  { 360 kgf*cm, 26 ft.*lbf }

  9. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (w/o VGRS)


    1. Install the clamp to the steering column hole shield.

    2. A01GKDGE02
      Text in Illustration
      *a Matchmark

      Align the matchmarks on the No. 2 steering intermediate shaft and steering column.

    3. Install the bolt.

      Torque:
      35 N*m  { 360 kgf*cm, 26 ft.*lbf }

  10. INSTALL STEERING INTERMEDIATE SHAFT (w/o VGRS)


    1. A01GLDLE02
      Text in Illustration
      *a Matchmark

      Align the matchmarks on the steering intermediate shaft and power steering link.

    2. Install the bolt.

      Torque:
      35 N*m  { 360 kgf*cm, 26 ft.*lbf }

  11. INSTALL STEERING SLIDING YOKE WITH SHAFT SUB-ASSEMBLY (w/ VGRS)


    1. A01GLIGE02
      Text in Illustration
      *a Matchmark

      Align the matchmarks on the No. 2 steering intermediate shaft assembly and steering sliding with shaft yoke.

    2. Align the matchmarks on the steering sliding with shaft yoke and power steering link.

    3. Temporarily install bolt B.

      Note

      Do not tighten the bolt.

    4. A01GJFBE02
      Text in Illustration
      *a Front of the vehicle

      Install bolt A and tighten bolt B.

      Torque:
      35 N*m  { 360 kgf*cm, 26 ft.*lbf }

  12. INSTALL STEERING SLIDING YOKE WITH SHAFT SUB-ASSEMBLY (w/o VGRS)


    1. A01GLIGE02
      Text in Illustration
      *a Matchmark

      Align the matchmarks on the No. 2 steering intermediate shaft and steering sliding with shaft yoke.

    2. Align the matchmarks on the steering sliding with shaft yoke and steering intermediate shaft.

    3. Temporarily install bolt B.

      Note

      Do not tighten the bolt.

    4. A01GJFBE02
      Text in Illustration
      *a Front of the vehicle

      Install bolt A and tighten bolt B.

      Torque:
      35 N*m  { 360 kgf*cm, 26 ft.*lbf }

  13. INSTALL GENERATOR ASSEMBLY

    A01GHPM

    1. Using an E8 "TORX" socket wrench, set the generator with the 2 stud bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. A01GLG5

      Install the generator with the 2 bolts and 2 nuts.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
    3. A01GN07

      Connect the generator connector.

    4. Connect the harness to the +B terminal with the nut.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  14. INSTALL V-RIBBED BELT


    1. A01GMNLE01

      Install the V belt as shown in the illustration.

      Note

      Check that the drive belt is properly set to each pulley.


      1. Rotate the tensioner pulley counterclockwise, and then remove the fix bar.

  15. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH

    Click here

  16. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH

    Tech Tips

    Use the same procedure described for the LH side.

  17. 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 }

  18. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  19. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  20. INSTALL COWL TOP VENTILATOR LOUVER RH


    1. A01GM4S

      Install the 6 clips and cowl top ventilator louver RH.

      Note

      If the cowl top ventilator louver RH is not properly installed, water may leak into the engine room and cause malfunctions. Therefore, make sure the cowl top ventilator louver RH is installed properly.

  21. INSPECT EXHAUST GAS LEAK

  22. INSTALL FRONT SUSPENSION MEMBER PROTECTOR LOWER


    1. Install the front suspension member protector lower with the 8 bolts.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  23. INSTALL NO. 1 ENGINE UNDER COVER


    1. Install the No. 1 engine under cover with the 13 screws and 7 clips.

  24. INSTALL ENGINE ROOM SIDE COVER RH


    1. Install the engine room side cover RH with the 5 clips.

  25. INSTALL ENGINE ROOM SIDE COVER LH


    1. Install the engine room side cover LH with the 5 clips.

  26. INSTALL INTAKE AIR CONNECTOR PIPE


    1. Align the protrusion of the intake air resonator with the cutout of the bracket and insert the protrusion.

    2. Install the intake air connector pipe with the 3 hose clamps.

      Torque:
      for intake air connector pipe and throttle body
      4.8 N*m  { 49 kgf*cm, 42 in.*lbf }
      for intake air connector pipe and air cleaner cap
      3.8 N*m  { 39 kgf*cm, 34 in.*lbf }

      Tech Tips


      • Insert the protrusion of the intake air connector pipe into the hole of the hose clamp.

      • The intake air connector pipe and throttle body clamp can be tightened within the range of 4.0 N*m (41 kgf*cm, 35 in.*lbf) to 5.5 N*m (56 kgf*cm, 49 in.*lbf), and the intake air connector pipe and air cleaner cap clamp can be tightened within the range of 2.0 N*m (20 kgf*cm, 18 in.*lbf) to 5.5 N*m (56 kgf*cm, 49 in.*lbf).

    3. Attach the 2 wire harness clamps.

    4. A01GMMEE03

      Connect the No. 1 and No. 2 ventilation hoses to the intake air connector pipe.

      Tech Tips


      • Position the claws of the clamps as shown in the illustration.

      • Install the clamps so that they are within the hose's paint marks.

  27. INSTALL NO. 1 AIR CLEANER INLET

    A01GME8E01

    1. Align the holes with the connection areas labeled A, and attach the No. 1 air cleaner inlet.

    2. A01GM3N

      Install the No. 1 air cleaner inlet with the 2 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  28. INSTALL AIR CLEANER INLET COVER SUB-ASSEMBLY

    A01GNHGE01

    1. Attach the 4 clips B.

      Note


      • Make sure the clips are attached securely.

      • Attaching the clips forcefully or hitting the top of the clips may damage them.

    2. Install the air cleaner inlet cover sub-assembly with the 5 clips labeled A.

  29. INSTALL V-BANK COVER SUB-ASSEMBLY

    A01GLQ5E01

    1. After sliding the cover from the vehicle front to the rear to attaching the 2 clips labeled A, attach the 4 clips labeled B and install the V-bank cover sub-assembly.

      Note


      • Make sure the clips are attached securely.

      • Attaching the clips forcefully or hitting the top of the clips may damage them.