Installation
3UR-FE EXHAUST: EXHAUST MANIFOLD: INSTALLATION
1. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
(a) Install a new gasket to the cylinder head and a new gasket to the No. 2 air tube.
HINT
* Install the exhaust manifold gasket with the gasket tab facing toward the front of the engine.
* Install the air tube gasket with the gasket's claws facing the tube side.
(b) Temporarily install the exhaust manifold and then uniformly tighten 8 new nuts that are not labeled A. Then tighten the new nuts labeled A in the illustration.
for nut A - Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
except nut A - Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
2. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
(a) Install the heat insulator with the 3 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
3. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
(a) Install a new gasket to the cylinder head and a new gasket to the No. 3 air tube.
HINT
* Install the exhaust manifold gasket with the gasket tab facing toward the rear of the engine.
* Install the air tube gasket with the gasket's claws facing the tube side.
(b) Temporarily install the exhaust manifold and then uniformly tighten 8 new nuts that are not labeled A. Then tighten the new nuts labeled A in the illustration.
for nut A - Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
except nut A - Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
4. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
(a) Install the heat insulator with the 3 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
5. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY
(a) Align the matchmarks and insert the No. 2 intermediate shaft into the intermediate shaft.
(b) Align the matchmarks and insert the No. 2 intermediate shaft into the power steering gear.
(c) Install the 2 bolts.
Torque : 35 Nm (357 kgf-cm, 26 ft-lbf)
6. 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.
7. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY (except Regular Cab Standard Deck)
(a) Connect the front No. 2 exhaust pipe to the exhaust pipe 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 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 new 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.
9. INSTALL FRONT PROPELLER SHAFT ASSEMBLY (for 4WD) Installation
10. INSTALL PROPELLER SHAFT HEAT INSULATOR (for 4WD)
(a) Install the heat insulator with the 2 bolts.
Torque : 16 Nm (163 kgf-cm, 12 ft-lbf)
11. CONNECT COOLER COMPRESSOR ASSEMBLY Installation
12. INSTALL GENERATOR ASSEMBLY Installation
13. CONNECT VANE PUMP ASSEMBLY Installation
14. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE Installation
15. INSTALL FAN SHROUD Installation
16. INSTALL FAN & GENERATOR V BELT Installation
17. CONNECT OUTLET RADIATOR HOSE
18. CONNECT INLET RADIATOR HOSE
19. INSTALL AIR CLEANER ASSEMBLY Installation
20. INSTALL AIR CLEANER HOSE ASSEMBLY Installation
21. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
22. ADD ENGINE COOLANT Service and Repair
23. INSPECT FOR COOLANT LEAK Testing and Inspection
24. INSPECT FOR EXHAUST GAS LEAK
If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.
25. INSTALL FRONT FENDER APRON SEAL REAR LH
(a) Install the fender apron seal with the 5 clips.
26. INSTALL FRONT FENDER APRON SEAL LH
(a) Install the fender apron seal with the 6 clips.
27. INSTALL FRONT FENDER APRON SEAL REAR RH
(a) Install the fender apron seal with the 5 clips.
28. INSTALL FRONT FENDER APRON SEAL RH
(a) Install the fender apron seal with the 6 clips.
29. INSTALL NO. 1 ENGINE UNDER COVER Replacement
30. INSTALL V-BANK COVER SUB-ASSEMBLY Installation