Installation

2GR-FXE 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) Install the exhaust manifold sub-assembly LH with the 6 new nuts and tighten the 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 with the bolt and nut and tighten 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

(a) Install a new O-ring to the No. 2 engine oil level dipstick guide.

(b) Apply a light coat of engine oil to the O-ring.

(c) Push the end of the No. 2 engine oil level dipstick guide into the No. 1 engine oil level dipstick guide.

(d) Install the No. 2 engine oil level dipstick guide with the bolt.

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

(e) Install the engine oil level dipstick.

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) Install the exhaust manifold sub-assembly RH with the 6 new nuts and tighten the 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 a new gasket and No. 1 EGR pipe with the bolt and 2 nuts.

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

12. INSTALL MANIFOLD STAY

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

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

for 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) Install a new gasket to the front No. 3 exhaust pipe sub-assembly.

(c) Using a plastic-faced hammer and wooden block, tap on 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 with the exhaust pipe when connecting the pipe.

(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 new nuts.

for bolt A - Torque : 55 Nm (561 kgf-cm, 41 ft-lbf)

for bolt B - Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)

for nut - Torque : 55 Nm (561 kgf-cm, 41 ft-lbf)

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

14. INSTALL FRONT FLOOR COVER LH Installation

15. INSTALL NO. 2 RADIATOR ASSEMBLY

Installation

16. INSTALL EGR COOLER ASSEMBLY

Installation

17. INSPECT FOR EXHAUST GAS LEAK

If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.