EXHAUST MANIFOLD INSTALLATION


  1. INSTALL AIR FUEL RATIO SENSOR NO.2 (for Bank 2 Sensor 1)


    1. A01NDM2E01
      Text in Illustration
      *1

      Fulcrum Length

      30 mm
      *2

      Fulcrum Length

      300 mm

      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. INSTALL EXHAUST MANIFOLD TO HEAD GASKET LH


    1. A01NHE4E01

      Install a new exhaust manifold to head gasket LH.

  3. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH


    1. A01NGUOE01

      Using a 12 mm deep socket wrench, install the exhaust manifold sub-assembly LH and 6 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. A01NDHM

      Install the No. 2 exhaust manifold heat insulator with the 3 bolts.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }
    2. A01NHIN

      Connect the sensor wire to the radiator pipe clamp.

    3. Connect the air fuel ratio sensor connector (for Bank 2 Sensor 1).

  5. INSTALL NO. 2 MANIFOLD STAY


    1. A01NERIE01

      Install the No. 2 manifold stay by tightening the bolt and nut in the order shown in the illustration.

      Torque:
      34 N*m  { 347 kgf*cm, 25 ft.*lbf }

  6. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A01NEKR

      Install a new O-ring to the No. 2 engine oil level dipstick guide.

    2. Apply a light coat of engine oil to the O-ring.

    3. Push in the No. 2 engine oil level dipstick guide end into the No. 1 engine oil level dipstick guide.

    4. A01NDZG

      Install the No. 2 engine oil level dipstick guide with the bolt.

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

    5. Install the engine oil level dipstick.

  7. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. Install a new gasket to the front exhaust pipe assembly.

    2. A01NEJVE01

      Install the front exhaust pipe assembly with the 2 nuts and 2 bolts (B).

      Torque:
      Bolt B
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Nut
      55 N*m  { 561 kgf*cm, 40 ft.*lbf }

    3. Tighten the bolt (A).

      Torque:
      Bolt A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    4. A01NE9S

      Connect the clamp and No. 2 oxygen sensor connector (for Bank 2 Sensor 2).

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

    Tech Tips

    Use the same procedure for bank 1 and bank 2.

    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.

  9. INSTALL EXHAUST MANIFOLD TO HEAD GASKET


    1. A01NF74E01

      Install a new exhaust manifold to head gasket.

  10. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH


    1. A01ND81E01

      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. A01NFH3

      Connect the 2 clamps and air fuel ratio sensor connector (for Bank 1 Sensor 1).

  11. INSTALL NO. 1 EGR PIPE


    1. A01NHTU

      Install 2 new gaskets and No. 1 EGR pipe with the bolt and 4 nuts.

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

  12. INSTALL MANIFOLD STAY


    1. A01NHRZ

      Install the manifold stay with the bolt and nut.

      Torque:
      Bolt
      34 N*m  { 347 kgf*cm, 25 ft.*lbf }
      Nut
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

  13. INSTALL FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY


    1. A01NGY9

      Using a vernier caliper, measure the free length of the compression springs.

      Minimum length
      41.5 mm (1.64 in.)

      If the free length is less than the minimum, replace the compression spring.

    2. Fully insert a new gasket to the front No. 3 exhaust pipe sub-assembly.

    3. A01NE1VE15
      Text in Illustration
      *1 Front No. 3 Exhaust Pipe Sub-assembly
      *2 Gasket
      *3 Wooden Block

      Using a plastic hammer and wooden block, tap in the new gasket until its surface is flush with the front No. 3 exhaust pipe sub-assembly.

      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 front No. 3 exhaust pipe sub-assembly.

    5. A01NE0JE01

      Install the front No. 3 exhaust pipe sub-assembly with the 4 bolts, 2 compression springs and 2 nuts.

      Torque:
      Bolt A
      55 N*m  { 561 kgf*cm, 40 ft.*lbf }
      Bolt B
      43 N*m  { 440 kgf*cm, 32 ft.*lbf }
      Nut
      55 N*m  { 561 kgf*cm, 40 ft.*lbf }
    6. A01NFHS

      Connect the 3 clamps and oxygen sensor connector (for Bank 1 Sensor 2).

  14. INSTALL FRONT FLOOR COVER LH


    1. A01NH2WE01
      Text in Illustration
      *1 Bolt
      *2 Screw

      Connect the 2 clips (B).

    2. Install the front floor cover LH with the 2 screws and 4 bolts.

    3. Install the clip (A).

  15. INSTALL NO. 2 RADIATOR ASSEMBLY


    1. Install the No. 2 radiator assembly Click here.

  16. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY


    1. A01NFEQE01

      Install the outer cowl top panel sub-assembly with the 4 bolts, 4 nuts*1 and 2 nuts*2.

      Torque:
      Nut*1
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }
      Nut*2
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }
      Bolt
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }
    2. A01NHCW

      Engage the grommet and clamp.

    3. Connect the connector (w/ Windshield Deicer).

  17. INSTALL FRONT SHOCK ABSORBER CAP LH (w/ Air Suspension)


    1. A01NHTO

      Install the front shock absorber cap with the 3 nuts.

      Torque:
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }

  18. INSTALL FRONT SHOCK ABSORBER CAP RH (w/ Air Suspension)

    Tech Tips

    Use the same procedure for the LH side and RH side.

  19. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY


    1. Install the windshield wiper motor and link assembly Click here.

  20. INSPECT FOR EXHAUST GAS LEAK