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EXHAUST MANIFOLD INSTALLATION

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  1. Click here

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


    1. A0158IBE03

      Using SST, install the air fuel ratio sensor.

      09224-00010
      without SST
      44 N*m 449 kgf*cm 32 ft.*lbf
      with SST
      40 N*m 408 kgf*cm 30 ft.*lbf
      Table 1. Text in Illustration
      *1 Fulcrum Length
      Tip:

      • 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. Click here

    INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH


    1. A0159MME03

      Install a new gasket to the cylinder head.

      Table 2. Text in Illustration
      *1 Protrusion
      A015DIT Front
      Note:

      Be careful of the installation direction.

    2. Temporarily install the manifold with 6 new nuts.

    3. A0156P3E02

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

      21 N*m 214 kgf*cm 15 ft.*lbf
      Table 3. Text in Illustration
      *A w/ Secondary Air Injection System
      *B w/o Secondary Air Injection System

    4. Connect the air fuel ratio sensor connector.

  3. Click here

    INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the heat insulator with the 3 bolts.

      13 N*m 133 kgf*cm 10 ft.*lbf
  4. Click here

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


    1. A015ASJE02

      Install 2 new gaskets.

      Table 4. Text in Illustration
      *1 Claw
      *2 No. 2 Air Tube
      Note:

      Make sure the gasket's claws are not caught between the No. 2 emission control valve set and No. 2 air tube.

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

      10 N*m 102 kgf*cm 7 ft.*lbf
  5. Click here

    INSTALL NO. 2 MANIFOLD STAY


    1. Install the No. 2 manifold stay with the 3 bolts.

      40 N*m 408 kgf*cm 30 ft.*lbf
  6. Click here

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


    1. A01563NE03

      Using SST, install the air fuel ratio sensor.

      09224-00010
      without SST
      44 N*m 449 kgf*cm 32 ft.*lbf
      with SST
      40 N*m 408 kgf*cm 30 ft.*lbf
      Table 5. Text in Illustration
      *1 Fulcrum Length
      Tip:

      • 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.

  7. Click here

    INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH


    1. A0156IPE03

      Install a new gasket to the cylinder head.

      Table 6. Text in Illustration
      *1 Protrusion
      A015DIT Front
      Note:

      Be careful of the installation direction.

    2. Temporarily install the manifold with 6 new nuts.

    3. A015B0ZE02

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

      21 N*m 214 kgf*cm 15 ft.*lbf
      Table 7. Text in Illustration
      *A w/ Secondary Air Injection System
      *B w/o Secondary Air Injection System

    4. Connect the air fuel ratio sensor connector.

  8. Click here

    INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the heat insulator with the 3 bolts.

      13 N*m 133 kgf*cm 10 ft.*lbf
  9. Click here

    CONNECT NO. 2 STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY


    • for Manual Tilt and Manual Telescopic Steering Column: (Click here)

    • for Power Tilt and Power Telescopic Steering Column: (Click here)

  10. Click here

    INSTALL AIR TUBE (w/ Secondary Air Injection System)


    1. A015DETE02

      Install 2 new gaskets.

      Table 8. Text in Illustration
      *1 Claw
      *2 Air Tube
      Note:

      Make sure the gasket's claws are not caught between the No. 1 emission control valve set and air tube.

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

      10 N*m 102 kgf*cm 7 in.*lbf
  11. Click here

    INSTALL MANIFOLD STAY


    1. Install the manifold stay with the 3 bolts.

      40 N*m 408 kgf*cm 30 ft.*lbf
  12. Click here

    INSTALL FRONT EXHAUST PIPE ASSEMBLY

    (Click here)

  13. Click here

    INSTALL NO. 2 ENGINE UNDER COVER


    1. Install the No. 2 engine under cover with the 2 bolts.

      29 N*m 296 kgf*cm 21 ft.*lbf
  14. Click here

    INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY


    1. Install the No. 1 engine under cover with the 10 bolts.

      29 N*m 296 kgf*cm 21 ft.*lbf
  15. Click here

    INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH


    1. Push in the clip to install the front fender splash shield sub-assembly RH.

    2. Install the 3 bolts and 2 screws.

  16. Click here

    INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH


    1. Push in the clip to install the front fender splash shield sub-assembly LH.

    2. Install the 3 bolts and screw.

  17. Click here

    INSTALL AIR CLEANER CASE SUB-ASSEMBLY


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

      5.0 N*m 51 kgf*cm 44 in.*lbf

    2. Install the air cleaner filter element.

  18. Click here

    INSTALL AIR CLEANER CAP AND HOSE


    1. A01592HE01

      Install the air cleaner cap and hose.

      Table 9. Text in Illustration
      *a Top
      *b Front
      *c Protrusion (Hose)
      *d Protrusion (Throttle body)

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

        5.0 N*m 51 kgf*cm 44 in.*lbf

      2. Tighten the clamp.

        2.5 N*m 25 kgf*cm 22 in.*lbf

      3. Attach the 4 clamps and connect the No. 2 PCV hose, vacuum hose and mass air flow meter connector.

        Tip:

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

  19. Click here

    INSTALL V-BANK COVER


    1. A015D9LE01

      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.

      Table 10. Text in Illustration
      *1 Pin
      *2 Hook
  20. Click here

    INSPECT FOR EXHAUST GAS LEAK


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

  21. Click here

    INSTALL FRONT FENDER APRON TRIM PACKING B


    1. w/ KDSS:

      Install the front fender apron trim packing B with the 3 clips.

    2. w/o KDSS:

      Install the front fender apron trim packing B with the 4 clips.

  22. Click here

    INSTALL FRONT FENDER APRON TRIM PACKING A


    1. Install the front fender apron trim packing A with the 3 clips.

  23. Click here

    INSTALL FRONT FENDER APRON TRIM PACKING D


    1. Install the front fender apron trim packing D with the 4 clips.

  24. Click here

    INSTALL FRONT FENDER APRON TRIM PACKING C


    1. Install the front fender apron trim packing C with the 4 clips.