AIR FUEL RATIO SENSOR INSTALLATION

INSTALL AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1)
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 }
  Note
  
  The "with SST" torque value is effective when using SST with a fulcrum length of 30 mm (1.18 in.).
  
  The "with SST" torque value is effective when using a torque wrench with a fulcrum length of 300 mm (11.81 in.) Click here.
  
  The "with SST" torque value is effective when SST is parallel to the torque wrench.
2. Connect the air fuel ratio sensor connector.
INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
1. Using a 12 mm deep socket wrench, install the exhaust manifold sub-assembly RH by tightening the 6 nuts in the order shown in the illustration.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
2. Connect the air fuel ratio sensor connector (for Bank 1 Sensor 1).
INSTALL MANIFOLD STAY
1. Install the manifold stay with the bolt.
  
  Torque:
  
  34 N*m { 347 kgf*cm, 25 ft.*lbf }
INSTALL CENTER EXHAUST PIPE ASSEMBLY (for Front Side)
1. Using a vernier caliper, measure the free length of the compression springs.
  
  Minimum length
  
  43.0 mm (1.693 in.)
  
  If the free length is less than the minimum, replace the compression spring.
2. Fully insert a new gasket to the center exhaust pipe assembly (for Front Side).
3. Using a plastic hammer and wooden block, tap in the new gasket until its surface is flush with the center exhaust pipe assembly (for Front Side).
  Note
  
  Be sure to install the gasket in the correct direction.
  
  Do not reuse the gasket.
  
  Do not damage the gasket.
  
  Do not push in the gasket by using the exhaust pipe when connecting it.
4. Install 2 new gaskets to the center exhaust pipe assembly (for Front Side).
5. Install the center exhaust pipe assembly (for Front Side) with the 4 bolts, 2 compression springs and 2 nuts.
  
  Torque:
  
  Bolt
  
  43 N*m { 440 kgf*cm, 32 ft.*lbf }
  
  Nut
  
  62 N*m { 632 kgf*cm, 46 ft.*lbf }
INSTALL AIR CLEANER CAP SUB-ASSEMBLY
1. Install the air cleaner cap sub-assembly to the air cleaner case with the 2 clamps.
2. Connect the air cleaner hose to the throttle body with the hose clamp.
3. Connect the ventilation hose.
4. Connect the purge line hose.
5. Connect the 2 wire harness clamps and mass air flow meter connector.
INSTALL AIR FUEL RATIO SENSOR NO.2 (for Bank 2 Sensor 1)
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 }
  Note
  
  The "with SST" torque value is effective when using SST with a fulcrum length of 30 mm (1.18 in.).
  
  The "with SST" torque value is effective when using a torque wrench with a fulcrum length of 300 mm (11.81 in.) Click here.
  
  The "with SST" torque value is effective when SST is parallel to the torque wrench.
2. Connect the air fuel ratio sensor connector.
INSPECT FOR EXHAUST GAS LEAK
INSTALL V-BANK COVER SUB-ASSEMBLY
1. Fit the 3 retainers and install the V-bank cover sub-assembly.
INSTALL RADIATOR COVER SUB-ASSEMBLY (for ALPHARD)
1. Install the radiator cover sub-assembly with the 4 clips.
INSTALL RADIATOR COVER SUB-ASSEMBLY (for VELLFIRE)
1. Install the radiator cover sub-assembly with the 4 clips.
INSTALL COWL TOP PANEL OUTER SUB-ASSEMBLY
1. Install the outer cowl top panel with the 8 bolts.
  
  Torque:
  
  8.8 N*m { 90 kgf*cm, 78 in.*lbf }
2. Connect the 2 clamps to the outer cowl top panel.
3. Remove the protective tape.
INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY
1. Install the brake master cylinder reservoir with bracket to the outer cowl top panel with the 2 nuts.
  
  Torque:
  
  6.5 N*m { 66 kgf*cm, 58 in.*lbf }
INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY
1. Install the windshield wiper motor and link assembly Click here.
INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY
1. Engage the 15 claws.
  
  Tech Tips
  
  Before engaging the 15 claws, make sure that the claws are positioned correctly.
  
  Note
  
  Make sure that the claws are fully engaged.
2. Install the instrument cluster finish panel assembly with the bolt <C>.
INSTALL INSTRUMENT PANEL BOX ASSEMBLY
1. With the instrument panel box assembly opened approximately 60° from its closed position, engage the 2 hinges horizontally.
  
  Note
  
  Engaging the hinges from the top will deform the hinges. Be sure to install the instrument panel box assembly horizontally.
2. Slightly bend stoppers (A) and (B) in the directions indicated by the arrows in the illustration and engage the stoppers to install the instrument panel box assembly.
INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY
1. With the glove compartment door assembly opened approximately 55° from its closed position, engage the 2 hinges horizontally.
  
  Note
  
  Engaging the hinges from the top will deform the hinges. Be sure to install the glove compartment door assembly horizontally.
2. Slightly bend stoppers (A) and (B) in the directions indicated by the arrows in the illustration and engage the stoppers to install the glove compartment door assembly.
3. Engage the claw and connect the glove compartment door stopper.
INSTALL CENTER FLOOR CARPET COVER RH (for RHD)
1. Engage the 4 claws.
2. Install the center floor carpet cover RH with the 2 clips.
INSTALL CENTER FLOOR CARPET COVER RH (for LHD)
1. Engage the 5 claws.
2. Install the center floor carpet cover RH with the clip.
INSTALL CENTER FLOOR CARPET COVER LH
1. Engage the 4 claws.
2. Install the center floor carpet cover LH with the clip.
INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (for RHD)
1. Engage the 3 guides and 14 claws.
  
  Tech Tips
  
  Make sure that all claws around the entire circumference of the driver side knee airbag assembly are fully engaged.
  
  Note
  
  Make sure that the claws are fully engaged.
2. Install the lower instrument panel finish panel with the 3 screws <B>.
3. Engage the 3 claws and the fuel lid lock control cable assembly.
4. Engage the 3 claws and the hood lock control cable assembly.
INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (for LHD)
1. Engage the 3 guides, 13 claws and clip.
  
  Tech Tips
  
  Make sure that all claws around the entire circumference of the driver side knee airbag assembly are fully engaged.
  
  Note
  
  Make sure that the claws are fully engaged.
2. Install the lower instrument panel finish panel with the 3 screws <B>.
3. Connect the fuel filler opening lid lock sub-assembly to the fuel lid lock open lever sub-assembly.
4. Engage the 3 claws and the fuel lid lock control cable assembly.
5. Engage the 3 claws and the hood lock control cable assembly.
INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (for RHD)
1. Engage the 2 claws and DLC3.
2. Engage the clamp.
3. Connect the connector.
4. Engage the 2 claws and 2 guides.
  
  Note
  
  Make sure that the claws are fully engaged.
5. Install the No. 1 instrument panel under cover sub-assembly with the 2 screws <B>.
INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (for LHD)
1. Engage the clamp.
2. Connect each connector.
3. Engage the 2 claws and guide.
  
  Note
  
  Make sure that the claws are fully engaged.
4. Install the No. 1 instrument panel under cover sub-assembly with the 2 screws <B>.
INSTALL COWL SIDE TRIM BOARD RH (for RHD)
1. Engage the 2 guides, claw and clip to install the cowl side trim board RH.
2. Install the clip(A).
INSTALL COWL SIDE TRIM BOARD LH (for LHD)
1. Engage the 2 guides, claw and clip to install the cowl side trim board LH.
2. Install the clip(A).
INSTALL NO. 1 ENGINE UNDER COVER