Installation

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

INSTALLATION

1. INSTALL EXHAUST MANIFOLD TO HEAD GASKET LH





(a) Install a new exhaust manifold to head gasket LH.
2. 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, 15ft-lbf)
3. 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, 75in-lbf)
4. INSTALL NO. 2 OIL LEVEL DIPSTICK GUIDE





(a) Install a new O-ring to the No. 2 oil level dipstick guide.
(b) Apply a light coat of engine oil to the O-ring.
(c) Push in the No. 2 oil level dipstick guide end into the oil level dipstick guide.





(d) Install the No. 2 oil level dipstick guide with the bolt.
Torque: 21 Nm (214 kgf-cm, 15ft-lbf)
(e) Install the oil level dipstick.
5. INSTALL AIR FUEL RATIO SENSOR (for Bank 2 Sensor 1) Installation
6. 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, 25ft-lbf)
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, 15ft-lbf)
(b) Connect the air fuel ratio sensor connector (for Bank 1 Sensor 1).
11. INSTALL MANIFOLD STAY





(a) Install the manifold stay with the bolt and nut.
Torque: 34 Nm (347 kgf-cm, 25ft-lbf)
12. 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 - Torque: 43 Nm (440 kgf-cm, 32ft-lbf)
Nut - Torque: 55 Nm (561 kgf-cm, 40ft-lbf)





(f) Install the grommet to the vehicle.





(g) Connect the 2 clamps and oxygen sensor connector (for Bank 1 Sensor 2).
13. INSTALL INLET NO. 2 AIR CLEANER Installation
14. INSTALL COOL AIR INTAKE DUCT SEAL Installation
15. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for AWD)
(a) Install the propeller with center bearing shaft assembly Installation.
16. INSTALL NO. 2 ENGINE UNDER COVER
17. INSTALL NO. 1 ENGINE UNDER COVER
18. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH Installation
19. INSTALL FRONT DOOR SCUFF PLATE LH Installation
20. INSPECT FOR EXHAUST GAS LEAK