Installation

2ZR-FXE INTAKE / EXHAUST: EXHAUST MANIFOLD: INSTALLATION

1. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

(a) Install the No. 2 exhaust manifold heat insulator with the 3 bolts.





Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)

2. INSTALL EXHAUST MANIFOLD

(a) Install 2 new gaskets and the exhaust manifold with the 7 nuts.





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

3. INSTALL MANIFOLD STAY

(a) Install the manifold stay with the 3 bolts.





Torque : 43 Nm (440 kgf-cm, 32 ft-lbf)

4. INSTALL AIR FUEL RATIO SENSOR Installation

5. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

(a) Install the No. 1 exhaust manifold heat insulator with the 3 bolts.





Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)

6. INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR

(a) Install the No. 1 floor heat insulator with the 3 nuts.





Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)

7. INSTALL FRONT EXHAUST PIPE ASSEMBLY (w/ Exhaust Heat Recirculation System)

NOTICE:
When installing the water hose, ensure that the exhaust heat recirculation system is filled with coolant. Otherwise, the electric water pump may be damaged.

(a) Using a vernier caliper, measure the free length of the compression springs.









HINT
If the free length is less than minimum, replace the compression spring.

(b) Fully insert 2 new gaskets to the exhaust manifold and front exhaust pipe assembly.

(c) Using a plastic hammer and wooden block, tap in the new gaskets until its surface is flush with the exhaust manifold and front exhaust pipe assembly.









NOTICE:
* Be careful with the installation direction of the gaskets.
* Do not reuse the gaskets.
* Do not damage the gaskets.
* Do not push in the gasket by using the exhaust pipe when connecting it.
(d) Connect the front exhaust pipe assembly to the 3 exhaust pipe supports.

(e) Install the front exhaust pipe assembly with the 4 bolts and 4 compression springs.





Torque : 43 Nm (440 kgf-cm, 32 ft-lbf)

(f) Connect the 2 heater water hoses.





(g) Connect the 3 clamps and oxygen sensor connector.





8. INSTALL FRONT EXHAUST PIPE ASSEMBLY (w/o Exhaust Heat Recirculation System)

(a) Using a vernier caliper, measure the free length of the compression springs.









HINT
If the free length is less than minimum, replace the compression spring.

(b) Fully insert 2 new gaskets to the exhaust manifold and front exhaust pipe assembly.

(c) Using a plastic hammer and wooden block, tap in the new gaskets until its surface is flush with the exhaust manifold and front exhaust pipe assembly.









NOTICE:
* Be careful with the installation direction of the gaskets.
* Do not reuse the gaskets.
* Do not damage the gaskets.
* Do not push in the gasket by using the exhaust pipe when connecting it.
(d) Connect the front exhaust pipe assembly to the 3 exhaust pipe supports.

(e) Install the front exhaust pipe assembly with the 4 bolts and 4 compression springs.





Torque : 43 Nm (440 kgf-cm, 32 ft-lbf)

9. ADD COOLANT (for Engine with Exhaust Heat Recirculation System) Service and Repair

10. INSPECT FOR COOLANT LEAK (for Engine with Exhaust Heat Recirculation System) Cooling System

11. INSTALL FRONT CENTER FLOOR BRACE Installation

12. INSTALL FRONT NO. 3 ENGINE UNDER COVER Installation

13. INSTALL NO. 2 ENGINE UNDER COVER

14. INSTALL NO. 1 ENGINE UNDER COVER

15. INSPECT FOR EXHAUST GAS LEAK