Installation

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

1. INSTALL AIR FUEL RATIO SENSOR NO.2 (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 ENGINE 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 2 clamps and air fuel ratio sensor connector (for Bank 1 Sensor 1).





11. INSTALL NO. 1 EGR PIPE

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





Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

12. 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)

13. 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.)

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

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

(c) 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.

(d) Install 2 new gaskets to the front No. 3 exhaust pipe sub-assembly.

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





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

Bolt B - Torque : 43 Nm (440 kgf-cm, 32 ft-lbf)

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

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





14. INSTALL FRONT FLOOR COVER LH

(a) Connect the 2 clips (B).





Text in Illustration





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

(c) Install the clip (A).

15. INSTALL NO. 2 RADIATOR ASSEMBLY

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

16. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY Installation

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

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

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

19. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

(a) Install the windshield wiper motor and link assembly Installation.

20. INSPECT FOR EXHAUST GAS LEAK