Use a torque wrench with a fulcrum length of 300 mm (11.8 in.). When using a torque wrench with a fulcrum length that is not 300 mm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification ().

Make sure SST and the wrench are connected in a straight line.

2. INSTALL AIR FUEL RATIO SENSOR (for Bank 2 Sensor 1)

Temporarily install the air fuel ratio sensor to the exhaust manifold RH by hand.

Using SST, tighten the air fuel ratio sensor.

SST
09224-00010

Torque:
without SST:
44 N*m{ 449 kgf*cm, 32 ft.*lbf}
with SST:
40 N*m{ 408 kgf*cm, 30 ft.*lbf}

Text in Illustration
*1	Fulcrum Length

HINT:

Use a torque wrench with a fulcrum length of 300 mm (11.8 in.). When using a torque wrench with a fulcrum length that is not 300 mm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification ().

Make sure SST and the wrench are connected in a straight line.

3. INSTALL EXHAUST MANIFOLD ASSEMBLY RH

w/ Secondary Air Injection System:

Install a new gasket to the No. 3 air tube.

HINT:

Install the gasket with the claws of the gasket facing the tube.

Install a new gasket to the cylinder head.

Text in Illustration
*1	Tab
*a	Front

HINT:

Install the gasket with the gasket tab facing toward the front of the engine.

w/ Secondary Air Injection System:

Install the exhaust manifold to the cylinder head with the 7 new nuts labeled A.

Torque:
21 N*m{ 214 kgf*cm, 15 ft.*lbf}

Install the exhaust manifold to the No. 3 air tube with the 2 nuts labeled B.

Torque:
10 N*m{ 102 kgf*cm, 7 ft.*lbf}

w/o Secondary Air Injection System:

Install the exhaust manifold with 7 new nuts.

Torque:
21 N*m{ 214 kgf*cm, 15 ft.*lbf}

Connect the air fuel ratio sensor connector and attach the wire harness clamp.

4. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

Install the heat insulator with 3 new bolts.

Torque:
10 N*m{ 102 kgf*cm, 7 ft.*lbf}

5. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

Apply engine oil to a new O-ring, and then install the O-ring to the engine oil level dipstick guide.

Install the engine oil level dipstick guide with the bolt.

Torque:
10 N*m{ 102 kgf*cm, 7 ft.*lbf}

Attach the engine wire clamp.

Install the engine oil level dipstick.

6. INSTALL MANIFOLD STAY

Temporarily install the manifold stay with the 3 bolts.

Tighten the 3 bolts in the sequence shown in the illustration.

Torque:
40 N*m{ 408 kgf*cm, 30 ft.*lbf}

7. INSTALL EXHAUST MANIFOLD ASSEMBLY LH

w/ Secondary Air Injection System:

Install a new gasket to the No. 4 air tube.

HINT:

Install the gasket with the claws of the gasket facing the tube.

Install a new gasket to the cylinder head.

Text in Illustration
*1	Tab
*a	Front

HINT:

Install the gasket with the gasket tab facing toward the rear of the engine.

w/ Secondary Air Injection System:

Install the exhaust manifold to the cylinder head with the 7 new nuts labeled A.

Torque:
21 N*m{ 214 kgf*cm, 15 ft.*lbf}

Install the exhaust manifold to the No. 4 air tube with the 2 nuts labeled B.

Torque:
10 N*m{ 102 kgf*cm, 7 ft.*lbf}

w/o Secondary Air Injection System:

Install the exhaust manifold with 7 new nuts.

Torque:
21 N*m{ 214 kgf*cm, 15 ft.*lbf}

Connect the air fuel ratio sensor connector and attach the wire harness clamp.

8. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

Install the heat insulator with 3 new bolts.

Torque:
10 N*m{ 102 kgf*cm, 7 ft.*lbf}

9. INSTALL NO. 2 MANIFOLD STAY

Temporarily install the manifold stay with the 3 bolts.

Tighten the 3 bolts in the sequence shown in the illustration.

Torque:
40 N*m{ 408 kgf*cm, 30 ft.*lbf}

10. INSTALL PROPELLER SHAFT HEAT INSULATOR

Install the propeller shaft heat insulator with the 2 bolts.

Torque:
16 N*m{ 160 kgf*cm, 12 ft.*lbf}

11. INSTALL FRONT PROPELLER SHAFT ASSEMBLY

()

12. INSTALL FRONT EXHAUST PIPE ASSEMBLY

()

13. INSPECT FOR EXHAUST GAS LEAK

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

14. INSTALL FRONT FENDER APRON TRIM PACKING C

Install the front fender apron trim packing C with the 4 clips.

15. INSTALL FRONT FENDER APRON TRIM PACKING A

Install the front fender apron trim packing A with the 3 clips.

16. INSTALL FRONT FENDER APRON TRIM PACKING D

Install the front fender apron trim packing D with the 4 clips.

17. INSTALL FRONT FENDER APRON TRIM PACKING B

w/ KDSS

Install the front fender apron trim packing B with the 3 clips.

w/o KDSS

Install the front fender apron trim packing B with the 4 clips.

18. INSTALL NO. 2 ENGINE UNDER COVER

Install the No. 2 engine under cover with the 2 bolts.

Torque:
29 N*m{ 296 kgf*cm, 21 ft.*lbf}

19. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

Install the No. 1 engine under cover sub-assembly with the 10 bolts.

Torque:
29 N*m{ 296 kgf*cm, 21 ft.*lbf}

20. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

Push in the clip to install the front fender splash shield sub-assembly RH.

Install the 3 bolts and 2 screws.

21. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH

Push in the clip to install the front fender splash shield sub-assembly LH.

Install the 3 bolts and screw.

22. INSTALL AIR CLEANER AND HOSE

Install the air cleaner and hose with the 3 bolts, and then tighten the hose clamp.

Torque:
for bolt:
5.0 N*m{ 51 kgf*cm, 44 in.*lbf}
for hose clamp:
2.5 N*m{ 25 kgf*cm, 22 in.*lbf}

Attach the clamp and connect the mass air flow meter connector.

Connect the No. 2 PCV hose and No. 1 air hose.

23. INSTALL V-BANK COVER SUB-ASSEMBLY

Attach the 2 V-bank cover hooks to the bracket. Then align the 3 V-bank cover grommets with the 3 pins, and press down on the V-bank cover to attach the pins.

Text in Illustration
*1	Grommet
*2	Pin
*3	Hook
*4	Bracket

1UR-FE INTAKE / EXHAUST

Land Cruiser URJ200 URJ202 GRJ200 VDJ200

EXHAUST MANIFOLD