EXHAUST MANIFOLD (for 2WD) INSTALLATION


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

    A01GN2XE01

    1. Using SST, install the air fuel ratio sensor to 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.

  2. INSTALL AIR FUEL RATIO SENSOR (for Bank 2 Sensor 1)

    A01GM4XE01

    1. Using SST, install the air fuel ratio sensor to 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.

  3. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH


    1. A01GJ4K

      Install a new gasket.

      Text in Illustration
      A01GKOV Front
    2. A01GKNIE02

      Install the exhaust manifold LH, and install 8 new nuts in the order shown in the illustration.

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

  4. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01GKZT

      Install the exhaust manifold heat insulator with the 3 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. A01GLSA

      Connect the air fuel ratio sensor connector.

  5. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH


    1. A01GK39

      Install a new gasket.

      Text in Illustration
      A01GKOV Front
    2. A01GMH5E02

      Install the exhaust manifold RH, and install 8 new nuts in the order shown in the illustration.

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

  6. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01GLJH

      Install the No. 1 exhaust manifold heat insulator with the 3 bolts.

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

      Connect the air fuel ratio 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 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-ribbed belt as shown in the illustration.

      Note

      Check that the V-ribbed 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 FRONT EXHAUST PIPE ASSEMBLY

    Click here

  18. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  19. INSTALL COWL TOP VENTILATOR LOUVER


    1. A01GM4S

      for LHD:

      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.

    2. A01GI9P

      for RHD:

      Install the 6 clips and cowl top ventilator louver LH.

      Note

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

  20. INSPECT FOR EXHAUST GAS LEAK

  21. 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 }

  22. INSTALL NO. 1 ENGINE UNDER COVER


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

  23. INSTALL ENGINE ROOM SIDE COVER RH


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

  24. INSTALL ENGINE ROOM SIDE COVER LH


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

  25. INSTALL INTAKE AIR CONNECTOR PIPE


    1. Install the intake air sound creator.

      Tech Tips

      Only perform this procedure when replacement of the intake air sound creator is necessary.


      1. Install the intake air sound creator with the bolt and hose clamp.

        Torque:
        2.0 N*m  { 20 kgf*cm, 18 in.*lbf }

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

    3. 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).

    4. Attach the 2 wire harness clamps.

    5. 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.

  26. INSTALL NO. 1 AIR CLEANER INLET


    1. A01GIR0E02

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

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

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

  27. INSTALL AIR CLEANER INLET COVER SUB-ASSEMBLY


    1. A01GLYAE01

      Attach the 4 clips labeled 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.

  28. INSTALL V-BANK COVER SUB-ASSEMBLY


    1. A01GMKRE01

      Slide the cover from the vehicle front toward the rear of the vehicle to attach the 2 clips labeled A, and then attach the 4 clips labeled B to 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.

      • When attaching the clips labeled A, be sure to slide the cover from the front of the vehicle toward the rear of the vehicle.