EXHAUST MANIFOLD INSTALLATION

PROCEDURE

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

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

  3. INSTALL EXHAUST MANIFOLD ASSEMBLY RH

    1. A215352C01

      *1

      Claw

      *2

      Tab

      Install a new gasket to the cylinder head and a new gasket to the No. 3 air tube.

      Tip:
      • Install the exhaust manifold gasket with the gasket tab facing toward the front of the engine.

      • Install the air tube gasket with the claws of the gasket facing the tube.

    2. Temporarily install the exhaust manifold with 9 new nuts.

    3. Temporarily install the manifold stay with the 3 bolts.

    4. A278261E01

      Tighten the 3 bolts in the sequence shown in the illustration.

      40 N*m

      408 kgf*cm

      30 ft.*lbf

    5. A230814E01

      Uniformly tighten the 7 nuts that are not labeled A. Then tighten the 2 nuts labeled A in the illustration.

      for nut A

      10 N*m

      102 kgf*cm

      7 ft.*lbf

      except nut A

      21 N*m

      214 kgf*cm

      15 ft.*lbf

    6. Connect the air fuel ratio sensor connector.

      Tip:

      Hook the wire harness to the bracket.

  4. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    1. Install the heat insulator with the 3 bolts.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

  5. INSTALL EXHAUST MANIFOLD ASSEMBLY LH

    1. A215353C01

      *1

      Claw

      *2

      Tab

      Install a new gasket to the cylinder head and a new gasket to the No. 4 air tube.

      Tip:
      • Install the exhaust manifold gasket with the gasket tab facing toward the rear of the engine.

      • Install the air tube gasket with the claws of the gasket facing the tube.

    2. Temporarily install the exhaust manifold with 9 new nuts.

    3. Temporarily install the No. 2 manifold stay with the 3 bolts.

    4. A278262E01

      Tighten the 3 bolts in the sequence shown in the illustration.

      40 N*m

      408 kgf*cm

      30 ft.*lbf

    5. A278263E01

      Uniformly tighten the 7 nuts that are not labeled A. Then tighten the 2 nuts labeled A in the illustration.

      for nut A

      10 N*m

      102 kgf*cm

      7 ft.*lbf

      except nut A

      21 N*m

      214 kgf*cm

      15 ft.*lbf

    6. Connect the air fuel ratio sensor connector.

      Tip:

      Hook the wire harness to the bracket.

  6. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY

    1. Install 2 new gaskets.

    2. A278264E01

      Install the EGR pipe with 4 new nuts and tighten the nuts in the sequence shown in the illustration.

      21 N*m

      214 kgf*cm

      15 ft.*lbf

  7. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

    1. Install the heat insulator with the 3 bolts.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

  8. INSTALL FRONT PROPELLER SHAFT ASSEMBLY

  9. INSTALL PROPELLER SHAFT HEAT INSULATOR WITH BRACKET

  10. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    1. A076194C01

      *1

      Gasket

      *2

      Wooden Block

      Using a plastic-faced hammer and wooden block, tap in a new gasket until its surface is flush with the front exhaust pipe.

      Note:
      • Be sure to install the gasket so that it faces the correct direction.

      • Do not reuse the gasket.

      • Do not damage the gasket.

      • When connecting the exhaust pipe, do not push in the gasket with the exhaust pipe.

    2. Install a new gasket and the front exhaust pipe to the exhaust manifold RH with 2 new nuts.

      54 N*m

      554 kgf*cm

      40 ft.*lbf

    3. A128853

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

      Minimum free length

      42 mm (1.65 in.)

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

    4. Connect the front exhaust pipe to the center exhaust pipe with the 2 compression springs and 2 bolts.

      43 N*m

      438 kgf*cm

      32 ft.*lbf

    5. Connect the heated oxygen sensor connector.

      Tip:

      Hook the wire harness to the bracket.

  11. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY

    1. Install 2 new gaskets and the front No. 2 exhaust pipe to the exhaust manifold LH with 2 new nuts.

      54 N*m

      554 kgf*cm

      40 ft.*lbf

    2. Connect the front No. 2 exhaust pipe to the front exhaust pipe with the 2 bolts.

      48 N*m

      489 kgf*cm

      35 ft.*lbf

    3. Connect the front No. 2 exhaust pipe to the exhaust pipe support.

    4. Connect the heated oxygen sensor connector.

  12. INSTALL EXHAUST PIPE STOPPER BRACKET

    1. Install the stopper bracket with the 2 bolts.

      19 N*m

      194 kgf*cm

      14 ft.*lbf

  13. CONNECT COOLER COMPRESSOR ASSEMBLY

  14. INSTALL GENERATOR ASSEMBLY

    1. Install the generator (Click here).

  15. 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 dipstick guide.

    3. Install the dipstick guide with the bolt.

      21 N*m

      214 kgf*cm

      15 ft.*lbf

    4. Install the dipstick.

  16. INSTALL INTAKE MANIFOLD ASSEMBLY

    1. Install the intake manifold (Click here).

  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

  19. INSTALL FRONT FENDER APRON SEAL RH

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

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

  22. INSTALL REAR ENGINE UNDER COVER ASSEMBLY

  23. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

  24. INSTALL LOWER FRONT BUMPER COVER