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 .
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