From 08/2009

2GR-FE INTAKE / EXHAUST: EXHAUST MANIFOLD: INSTALLATION

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

2. INSTALL EXHAUST MANIFOLD TO HEAD GASKET LH

(a) Install a new exhaust manifold to head gasket LH.





3. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH

(a) 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 Nm (214 kgf-cm, 15 ft-lbf)

4. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

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





Torque : 8.5 Nm (87 kgf-cm, 75 in-lbf)

(b) Connect the sensor wire to the radiator pipe clamp.





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

5. INSTALL NO. 2 MANIFOLD STAY

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





Torque : 34 Nm (347 kgf-cm, 25 ft-lbf)

6. INSTALL NO. 2 OIL LEVEL DIPSTICK GUIDE Installation

7. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation

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

9. INSTALL EXHAUST MANIFOLD TO HEAD GASKET

(a) Install a new exhaust manifold to head gasket.





10. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH

(a) 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 Nm (214 kgf-cm, 15 ft-lbf)

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

11. INSTALL MANIFOLD STAY

(a) Install the manifold stay with the bolt and nut.





Bolt - Torque : 34 Nm (347 kgf-cm, 25 ft-lbf)

Nut - Torque : 35 Nm (357 kgf-cm, 26 ft-lbf)

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

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





Minimum length:

41.5 mm (1.64 in.)

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

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

(d) 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.





Text in Illustration





NOTICE:
* 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.
(e) Install 2 new gaskets to the front No. 3 exhaust pipe sub-assembly.

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





Bolt - Torque : 55 Nm (561 kgf-cm, 40 ft-lbf)

Nut - Torque : 55 Nm (561 kgf-cm, 40 ft-lbf)

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





13. INSTALL FRONT FLOOR COVER LH

(a) Connect the 3 clips.





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

14. INSTALL NO. 2 RADIATOR ASSEMBLY

(a) Install the No. 2 radiator assembly Installation.

15. INSPECT FOR EXHAUST GAS LEAK