EXHAUST MANIFOLD INSTALLATION


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


    1. A01DMD8E01
      Text in Illustration
      *a Fulcrum Length

      Using SST, install the sensor.

      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 30 cm (11.8 in.). When using a torque wrench with a fulcrum length that is not 30 cm (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 EXHAUST MANIFOLD SUB-ASSEMBLY LH


    1. A01DRL8E01
      Text in Illustration
      *1 Protrusion
      A01DQPB Front

      Install a new gasket to the cylinder head.

      Note

      Be careful of the installation direction.

    2. Temporarily install the manifold with 6 new nuts.

    3. Tighten the 6 nuts in the sequence shown in the illustration.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      A01DNGSE01
      Text in Illustration
      *1 w/ Secondary Air Injection System *2 w/o Secondary Air Injection System

    4. Connect the air fuel ratio sensor connector.

  3. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the heat insulator with the 3 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  4. INSTALL NO. 2 AIR TUBE (w/ Secondary Air Injection System)


    1. A01DS0TE01
      Text in Illustration
      *1 New Gasket
      *2 No. 2 Air Tube

      Install 2 new gaskets to the No. 2 air tube.

    2. Install the No. 2 air tube with the 2 bolts and 2 nuts.

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

  5. INSTALL MANIFOLD STAY


    1. Install the manifold stay with the 3 bolts.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

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


    1. A01DOXXE01
      Text in Illustration
      *a Fulcrum Length

      Using SST, install the sensor.

      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 30 cm (11.8 in.). When using a torque wrench with a fulcrum length that is not 30 cm (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.

  7. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH


    1. A01DMZ6E01
      Text in Illustration
      *1 Protrusion
      A01DQPB Front

      Install a new gasket to the cylinder head.

      Note

      Be careful of the installation direction.

    2. Temporarily install the manifold with 6 new nuts.

    3. Tighten the 6 nuts in the sequence shown in the illustration.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      A01DMLBE01
      Text in Illustration
      *1 w/ Secondary Air Injection System *2 w/o Secondary Air Injection System

    4. Connect the air fuel ratio sensor connector.

  8. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the heat insulator with the 3 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  9. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY (for RHD)


    1. for Manual Tilt and Manual Telescopic Steering Column:

      Connect the No. 2 steering intermediate shaft Click here.

    2. for Power Tilt and Power Telescopic Steering Column:

      Connect the No. 2 steering intermediate shaft Click here.

  10. INSTALL AIR TUBE (w/ Secondary Air Injection System)


    1. A01DQXXE01
      Text in Illustration
      *1 New Gasket
      *2 Air Tube

      Install 2 new gaskets to the air tube.

    2. Install the air tube with the 2 bolts and 2 nuts.

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

  11. INSTALL NO. 2 MANIFOLD STAY


    1. Install the manifold stay with the 3 bolts.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  12. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. Install the front exhaust pipe Click here.

  13. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    1. Install the air cleaner case with the 3 bolts.

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

    2. Attach the wire harness clamp.

    3. Install the air cleaner filter element.

  14. INSTALL AIR CLEANER CAP AND HOSE


    1. A01DTUYE01
      Text in Illustration
      *a Top
      *b Front
      *c RH
      *d Align cutout portion of hose with protrusion of throttle
      *e Paint Mark

      Install the air cleaner cap and hose.


      1. Install the air cleaner cap and hose with the bolt and fasten the 4 hook clamps.

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

      2. Tighten the clamp.

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

      3. Attach the 4 clamps and connect the ventilation hose, vacuum hose and mass air flow meter connector.

        Tech Tips

        The direction of the hose clamp is indicated in the illustration.

  15. INSTALL V-BANK COVER


    1. A01DQA1E01
      Text in Illustration
      *1 Pin
      *2 Hook

      Attach the 2 V-bank cover hooks to the bracket. Then align the 2 V-bank cover grommets with the 2 pins and press down on the V-bank cover to attach the pins.

  16. INSTALL UPPER RADIATOR SUPPORT SEAL


    1. Install the upper radiator support seal with the 13 clips.

  17. INSPECT FOR EXHAUST GAS LEAK


    • If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.

  18. INSTALL FRONT FENDER APRON SEAL LH


    1. w/ KDSS:

      Install the apron seal with the 7 clips.

    2. w/o KDSS:

      Install the apron seal with the 4 clips.

  19. INSTALL FRONT FENDER APRON SEAL RH


    1. Install the apron seal with the 5 clips.

  20. INSTALL FRONT NO. 1 FENDER APRON TO FRAME SEAL LH


    1. Install the frame seal with the 5 clips.

  21. INSTALL FRONT NO. 1 FENDER APRON TO FRAME SEAL RH


    1. Install the frame seal with the 5 clips.