INSTALLATION (To 8/2009): Installation

INSTALL AIR FUEL RATIO SENSOR (for Bank 2 Sensor 1) . Refer to INSTALLATION - Step 2
INSTALL EXHAUST MANIFOLD TO HEAD GASKET LH
1. Install a new exhaust manifold to head gasket LH.
  
  Fig 1: Locating Exhaust Manifold To Head Gasket LH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
1. Using a 12 mm deep socket wrench, install the exhaust manifold sub-assembly LH and 6 nuts in the order shown in the illustration.
  
  Fig 2: Install The Exhaust Manifold Sub-Assembly LH And 6 Nuts In The Order
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
1. Install the No. 2 exhaust manifold heat insulator with the 3 bolts.
  
  Fig 3: Install the No. 2 Exhaust Manifold Heat Insulator With The 3 Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf)
2. Connect the sensor wire to the radiator pipe clamp.
  
  Fig 4: Connect The Sensor Wire To The Radiator Pipe Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Connect the air fuel ratio sensor connector (for Bank 2 Sensor 1).
INSTALL NO. 2 MANIFOLD STAY
1. Install the No. 2 manifold stay by tightening the bolt and nut in the order shown in the illustration.
  
  Fig 5: Identifying No. 2 Manifold Stay Bolt & Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 34 N*m (347 kgf*cm, 25 ft.*lbf)
INSTALL NO. 2 OIL LEVEL DIPSTICK GUIDE . Refer to INSTALLATION - Step 13
INSTALL FRONT EXHAUST PIPE ASSEMBLY See step 2
INSTALL AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1) . Refer to INSTALLATION - Step 1
INSTALL EXHAUST MANIFOLD TO HEAD GASKET
1. Install a new exhaust manifold to head gasket.
  
  Fig 6: Locating Exhaust Manifold To Head Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
1. 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.
  
  Fig 7: Locating Exhaust Manifold Sub-Assembly And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
2. Connect the air fuel ratio sensor connector (for Bank 1 Sensor 1).
INSTALL MANIFOLD STAY
1. Install the manifold stay with the bolt and nut.
  
  Fig 8: Locating Manifold Stay Bolt And Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Bolt
  
  Torque: 34 N*m (347 kgf*cm, 25 ft.*lbf)
  
  Nut
  
  Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf)

INSTALL FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY

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

Fig 9: Measuring Free Length Of Compression Spring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Minimum length

41.5 mm (1.64 in.)

If the free length is less than the minimum, replace the compression spring.
Fully insert a new gasket to the front No. 3 exhaust pipe sub-assembly.

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.

Fig 10: Identifying Front No. 3 Exhaust Pipe Sub-Assembly, Wooden Block And Gasket

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	Front No. 3 Exhaust Pipe Sub-assembly
*2	Gasket
*3	Wooden Block

NOTE:

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.

Install 2 new gaskets to the front No. 3 exhaust pipe sub-assembly.
Install the front No. 3 exhaust pipe sub-assembly with the 4 bolts, 2 compression springs and 2 nuts.

Fig 11: Install The Front No. 3 Exhaust Pipe Sub-Assembly With The 4 Bolts, 2 Compression Springs And 2 Nuts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Bolt

Torque: 55 N*m (561 kgf*cm, 40 ft.*lbf)

Nut

Torque: 55 N*m (561 kgf*cm, 40 ft.*lbf)
Connect the 3 clamps and oxygen sensor connector (for Bank 1 Sensor 2).

Fig 12: Connect The 3 Clamps And Oxygen Sensor Connector (For Bank 1 Sensor 2)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL FRONT FLOOR COVER LH
1. Connect the 3 clips.
  
  Fig 13: Locating Front Floor Cover LH With Screws And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the front floor cover LH with the 2 screws and 4 bolts.
INSTALL NO. 2 RADIATOR ASSEMBLY
1. Install the No. 2 radiator assembly. Refer to INSTALLATION .
INSPECT FOR EXHAUST GAS LEAK