Installation
1GR-FE EXHAUST: EXHAUST MANIFOLD: INSTALLATION
1. INSTALL AIR FUEL RATIO SENSOR (for Bank 2 Sensor 1) Installation
2. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
(a) Install a new gasket onto the cylinder head.
Text in Illustration
NOTICE:
Be careful of the installation direction.
(b) Temporarily install the manifold with the 6 nuts.
(c) Tighten the 6 nuts in the sequence shown in the illustration.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
(d) Connect the air fuel ratio sensor connector.
3. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
(a) Install the heat insulator with the 3 bolts.
Torque : 13 Nm (133 kgf-cm, 10 ft-lbf)
4. INSTALL MANIFOLD STAY
(a) Install the manifold stay with the 3 bolts.
Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)
5. INSTALL AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1) Installation
6. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
(a) Install a new gasket onto the cylinder head.
Text in Illustration
NOTICE:
Be careful of the installation direction.
(b) Temporarily install the manifold with the 6 nuts.
(c) Tighten the 6 nuts in the sequence shown in the illustration.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
(d) Connect the air fuel ratio sensor connector.
7. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
(a) Install the heat insulator with the 3 bolts.
Torque : 13 Nm (133 kgf-cm, 10 ft-lbf)
8. INSTALL NO. 2 MANIFOLD STAY
(a) Install the manifold stay with the 3 bolts.
Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)
9. INSTALL FRONT EXHAUST PIPE ASSEMBLY
(a) Check the free length.
(1) Using vernier calipers, measure the free length of the compression spring.
Minimum:
40.5 mm (1.594 in.)
If the free length is less that the minimum, replace the compression spring.
(b) Install a new gasket onto the front exhaust pipe.
(1) Using a wooden block and plastic-faced hammer, tap in a new gasket until it is flush with the front exhaust pipe end.
Text in Illustration
NOTICE:
* Make sure that the gasket is in the correct direction when installing.
* Do not reuse the removed gasket.
* Do not push in the gasket with the exhaust pipe when connecting it.
(c) Install a new gasket onto the exhaust manifold RH.
(d) Install the front exhaust pipe with 2 new nuts, 2 bolts and the 2 compression springs.
Nut - Torque : 54 Nm (554 kgf-cm, 40 ft-lbf)
Bolt - Torque : 48 Nm (489 kgf-cm, 35 ft-lbf)
10. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY
(a) Install a new gasket onto the exhaust manifold LH.
(b) Install a new gasket onto the front No. 2 exhaust pipe.
(c) Install the front No. 2 exhaust pipe with the 2 bolts, 2 nuts and the exhaust pipe support.
Nut - Torque : 54 Nm (554 kgf-cm, 40 ft-lbf)
Bolt - Torque : 48 Nm (489 kgf-cm, 35 ft-lbf)
11. INSTALL EXHAUST PIPE STOPPER BRACKET (for 4WD)
(a) Install the exhaust pipe stopper bracket with the 2 bolts.
Torque : 19 Nm (194 kgf-cm, 14 ft-lbf)
12. INSTALL AIR CLEANER CASE SUB-ASSEMBLY Installation
13. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY Installation
14. INSTALL AIR CLEANER CAP AND HOSE Installation
15. INSTALL V-BANK COVER Installation
16. INSPECT FOR EXHAUST GAS LEAK
17. INSTALL FRONT FENDER APRON SEAL LH
(a) Install the apron seal with the 5 clips.
18. INSTALL FRONT FENDER APRON SEAL RH
(a) Install the apron seal with the 4 clips.
19. INSTALL FRONT NO. 1 FENDER APRON TO FRAME SEAL LH
(a) Install the frame seal with the 5 clips.
20. INSTALL FRONT NO. 1 FENDER APRON TO FRAME SEAL RH
(a) Install the frame seal with the 5 clips.