Exhaust Manifold -- Installation |
| 1. INSTALL AIR FUEL RATIO SENSOR (for Bank 2 Sensor 1) |
- HINT:
- for Automatic Transmission:
- Perform "Inspection After Repairs" after replacing the air fuel ratio sensor (LandCruiser RM000004NJC03SX.html).
Using SST, install the 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 *a Fulcrum Length - HINT:
- Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification (LandCruiser RM000003YMD00TX.html).
- Make sure SST and the wrench are connected in a straight line.
 |
| 2. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH |
Install a new gasket to the cylinder head.
Text in Illustration *1 Protrusion 
Front - NOTICE:
- Be careful of the installation direction.
 |
Temporarily install the manifold with 6 new nuts.
Tighten the 6 nuts in the sequence shown in the illustration.
- Torque:
- 21 N*m{214 kgf*cm, 15 ft.*lbf}
Text in Illustration *1 w/ Secondary Air Injection System *2 w/o Secondary Air Injection System
Connect the air fuel ratio sensor connector.
| 3. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR |
Install the heat insulator with the 3 bolts.
- Torque:
- 13 N*m{133 kgf*cm, 10 ft.*lbf}
| 4. INSTALL NO. 2 AIR TUBE (w/ Secondary Air Injection System) |
Install 2 new gaskets to the No. 2 air tube.
Text in Illustration *1 New Gasket *2 No. 2 Air Tube
 |
Install the No. 2 air tube with the 2 bolts and 2 nuts.
- Torque:
- 10 N*m{102 kgf*cm, 7 ft.*lbf}
| 5. INSTALL MANIFOLD STAY |
Install the manifold stay with the 3 bolts.
- Torque:
- 40 N*m{408 kgf*cm, 30 ft.*lbf}
| 6. INSTALL AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1) |
- HINT:
- for Automatic Transmission:
- Perform "Inspection After Repairs" after replacing the air fuel ratio sensor (LandCruiser RM000004NJC03SX.html).
Using SST, install the 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 *a Fulcrum Length - HINT:
- Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification (LandCruiser RM000003YMD00TX.html).
- Make sure SST and the wrench are connected in a straight line.
 |
| 7. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH |
Install a new gasket to the cylinder head.
Text in Illustration *1 Protrusion Front - NOTICE:
- Be careful of the installation direction.
 |
Temporarily install the manifold with 6 new nuts.
Tighten the 6 nuts in the sequence shown in the illustration.
- Torque:
- 21 N*m{214 kgf*cm, 15 ft.*lbf}
Text in Illustration *1 w/ Secondary Air Injection System *2 w/o Secondary Air Injection System
Connect the air fuel ratio sensor connector.
| 8. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR |
Install the heat insulator with the 3 bolts.
- Torque:
- 13 N*m{133 kgf*cm, 10 ft.*lbf}
| 9. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY (for RHD) |
for Manual Tilt and Manual Telescopic Steering Column:
Connect the No. 2 steering intermediate shaft (LandCruiser RM0000039SG031X.html).
for Power Tilt and Power Telescopic Steering Column:
Connect the No. 2 steering intermediate shaft (LandCruiser RM0000039SG032X.html).
| 10. INSTALL AIR TUBE (w/ Secondary Air Injection System) |
Install 2 new gaskets to the air tube.
Text in Illustration *1 New Gasket *2 Air Tube
 |
Install the air tube with the 2 bolts and 2 nuts.
- Torque:
- 10 N*m{102 kgf*cm, 7 in.*lbf}
| 11. INSTALL NO. 2 MANIFOLD STAY |
Install the manifold stay with the 3 bolts.
- Torque:
- 40 N*m{408 kgf*cm, 30 ft.*lbf}
| 12. INSTALL FRONT EXHAUST PIPE ASSEMBLY |
Install the front exhaust pipe (LandCruiser RM00000456H00TX.html).
| 13. INSTALL AIR CLEANER CASE SUB-ASSEMBLY |
Install the air cleaner case with the 3 bolts.
- Torque:
- 12 N*m{122 kgf*cm, 9 ft.*lbf}
Attach the wire harness clamp.
Install the air cleaner filter element.
| 14. INSTALL AIR CLEANER CAP AND HOSE |
Install the air cleaner cap and hose.
Text in Illustration *a Top *b Front *c RH *d Align cutout portion of hose with protrusion of throttle *e Paint Mark Install the air cleaner cap and hose with the bolt and fasten the 4 hook clamps.
- Torque:
- 5.0 N*m{51 kgf*cm, 44 in.*lbf}
Tighten the clamp.
- Torque:
- 5.0 N*m{51 kgf*cm, 44 in.*lbf}
Attach the 4 clamps and connect the ventilation hose, vacuum hose and mass air flow meter connector.
- HINT:
- The direction of the hose clamp is indicated in the illustration.
 |
| 15. INSTALL V-BANK COVER |
Attach the 2 V-bank cover hooks to the bracket. Then align the 2 V-bank cover grommets with the 2 pins and press down on the V-bank cover to attach the pins.
Text in Illustration *1 Pin *2 Hook
 |
| 16. INSTALL UPPER RADIATOR SUPPORT SEAL |
Install the upper radiator support seal with the 13 clips.
| 17. INSPECT FOR EXHAUST GAS LEAK |
- If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.
| 18. INSTALL FRONT FENDER APRON SEAL LH |
w/ KDSS:
Install the apron seal with the 7 clips.
w/o KDSS:
Install the apron seal with the 4 clips.
| 19. INSTALL FRONT FENDER APRON SEAL RH |
Install the apron seal with the 5 clips.
| 20. INSTALL FRONT NO. 1 FENDER APRON TO FRAME SEAL LH |
Install the frame seal with the 5 clips.
| 21. INSTALL FRONT NO. 1 FENDER APRON TO FRAME SEAL RH |
Install the frame seal with the 5 clips.