Installation

2UZ-FE EXHAUST: EXHAUST MANIFOLD:

INSTALLATION

1. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH





(a) Place a new gasket on the cylinder head with the "L" mark facing the manifold side.

NOTE: Be careful of the installation direction.





(b) Temporarily install the exhaust manifold, and then uniformly tighten 8 new nuts in several steps, in the sequence shown in the illustration.
Torque: 44 Nm (449 kgf-cm, 32 ft-lbf)
2. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
(a) Temporarily install the heat insulator with the 4 bolts.





(b) Uniformly tighten the 4 bolts in several steps, in the sequence shown in the illustration.
Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)
3. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY (Installation)

4. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH





(a) Place a new gasket on the cylinder head with the "R" mark facing the manifold side.

NOTE: Be careful of the installation direction.





(b) Temporarily install the exhaust manifold, and then uniformly tighten 8 new nuts in several steps, in the sequence shown in the illustration.
Torque: 44 Nm (428 kgf-cm, 31 ft-lbf)
5. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
(a) Temporarily install the heat insulator with the 4 bolts.





(b) Uniformly tighten the 4 bolts in several steps, in the sequence shown in the illustration.
Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)
6. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY (for Regular Cab Standard Deck)
(a) Install a new gasket and the front No. 2 exhaust pipe to the exhaust manifold LH with 3 new nuts.
Torque: 54 Nm (554 kgf-cm, 40 ft-lbf)
(b) Install a new gasket and the front No. 2 exhaust pipe to the front No. 3 exhaust pipe with the 2 bolts and 2 nuts.
Torque: 48 Nm (489 kgf-cm, 35 ft-lbf)
(c) Connect the air fuel ratio sensor connector.
(d) Connect the heated oxygen sensor connector.
7. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY (except Regular Cab Standard Deck)
(a) Connect the front No. 2 exhaust pipe to the exhaust support.
(b) Install a new gasket and the front No. 2 exhaust pipe to the exhaust manifold LH with 3 new nuts.
Torque: 54 Nm (554 kgf-cm, 40 ft-lbf)
(c) Install a new gasket and the front No. 2 exhaust pipe to the center exhaust pipe with the 2 bolts.
Torque: 48 Nm (489 kgf-cm, 35 ft-lbf)
(d) Connect the air fuel ratio sensor connector.
(e) Connect the heated oxygen sensor connector.
8. INSTALL FRONT PROPELLER SHAFT ASSEMBLY (for 4WD) (Installation)

9. INSTALL PROPELLER SHAFT HEAT INSULATOR (for 4WD)





(a) Install the heat insulator with the 2 bolts.
Torque: 16 Nm (160 kgf-cm, 12 ft-lbf)
10. INSTALL FRONT EXHAUST PIPE ASSEMBLY
(a) Install a new gasket and the front exhaust pipe to the exhaust manifold RH with 3 new nuts.
Torque: 54 Nm (554 kgf-cm, 40 ft-lbf)
(b) Install a new gasket and the front exhaust pipe to the center exhaust pipe with the 2 bolts.
Torque: 48 Nm (489 kgf-cm, 35 ft-lbf)
(c) Connect the air fuel ratio sensor connector.
(d) Connect the heated oxygen sensor connector and 2 clamps.
11. INSTALL AIR SWITCHING VALVE ASSEMBLY (Installation)

12. INSTALL NO. 2 AIR TUBE (for Bank 2) (Installation)

13. CONNECT NO. 2 AIR INJECTION SYSTEM HOSE (Installation)

14. INSTALL WATER BY-PASS PIPE ASSEMBLY





(a) Connect the 2 water hoses to the transmission oil cooler.
(b) Install the water by-pass pipe with the 3 bolts.
Torque: 18 Nm (184 kgf-cm, 13 ft-lbf)





15. CONNECT N0. 5 WATER BY-PASS HOSE





16. INSTALL HEATER OUTLET WATER HOSE
17. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE (Installation)

18. INSTALL AIR SWITCHING VALVE ASSEMBLY (for Bank 1) (Installation)

19. INSTALL NO. 3 AIR TUBE (for Bank 1) (Installation)

20. INSTALL NO. 2 AIR HOSE (for Bank 1) (Installation)

21. INSTALL AIR CLEANER ASSEMBLY (Installation)

22. INSTALL AIR CLEANER HOSE ASSEMBLY (Installation)

23. ADD ENGINE COOLANT (Service and Repair)

24. INSPECT FOR COOLANT LEAK (Testing and Inspection)

25. INSTALL THROTTLE BODY COVER SUB-ASSEMBLY (Installation)

26. INSTALL NO. 1 ENGINE UNDER COVER (Replacement)

27. INSPECT FOR EXHAUST GAS LEAK
If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.
28. INSTALL FRONT FENDER APRON SEAL LH
(a) Install the fender apron seal with the 6 clips.
29. INSTALL FRONT FENDER APRON SEAL REAR LH
(a) Install the fender apron seal with the 5 clips.
30. INSTALL FRONT FENDER APRON SEAL RH
(a) Install the fender apron seal with the 6 clips.
31. INSTALL FRONT FENDER APRON SEAL REAR RH
(a) Install the fender apron seal with the 5 clips.