Installation [08/2015 - ]: Procedure

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INSTALL STUD BOLT

NOTE:

If a stud bolt is deformed or its threads are damaged, replace it.

Using an E10 "TORX" socket wrench, install the stud bolt to the exhaust manifold converter sub-assembly (TWC: Front and Rear Catalyst).

Torque: 14.5 N.m (148 kgf/cm, 11 ft.lbf)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (TWC: Front and Rear Catalyst)

Set a new exhaust pipe clamp to the turbocharger sub-assembly.
NOTE:
Do not open the exhaust pipe clamp more than 140 mm (5.51 in.). The standard required opening should be approximately 60 mm (2.36 in.).
Temporarily install the turbocharger stay to the exhaust manifold converter sub-assembly (TWC: Front and Rear Catalyst) with the nut.
NOTE:
Tighten the nut by hand until it contacts the surface of the turbocharger stay.

Install a new outlet turbine elbow gasket to the exhaust manifold converter sub-assembly (TWC: Front and Rear Catalyst) as shown in the illustration.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Exhaust Manifold Converter Sub-assembly (TWC: Front and Rear Catalyst)
*2	Outlet Turbine Elbow Gasket
*a	1.5 mm (0.0591 in.) or less
*b	Knock Pin

NOTE:

When reusing the exhaust manifold converter sub-assembly (TWC: Front and Rear Catalyst), thoroughly clean the gasket groove.

HINT:

Make sure that the outlet turbine elbow gasket is securely installed into the gasket groove of the exhaust manifold converter sub-assembly (TWC: Front and Rear Catalyst).

Temporarily install the turbocharger stay to the stud bolt on the cylinder head sub-assembly side with the nut.
NOTE:
Tighten the nut by hand until it contacts the surface of the turbocharger stay.
While aligning the knock pin of the exhaust manifold converter sub-assembly (TWC: Front and Rear Catalyst) with the pin hole on the turbocharger sub-assembly, set the exhaust manifold converter sub-assembly (TWC: Front and Rear Catalyst) to the turbocharger sub-assembly.

While aligning the protrusion of the exhaust pipe clamp as shown in the illustration, temporarily install the exhaust pipe clamp.

*a	Protrusion on Exhaust Pipe Clamp Side
*b	Protrusion on Exhaust Manifold Converter Sub-assembly (TWC: Front and Rear Catalyst) Side
*c	Alignment Area

Tighten the exhaust pipe clamp.
Torque: 25 N.m (255 kgf/cm, 18 ft.lbf)
Tighten the 2 nuts in the order shown in the illustration.

Fig 1: Exhaust Pipe Clamp Tightening Sequence
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 43 N.m (438 kgf/cm, 32 ft.lbf)

INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
1. Install the No. 2 exhaust manifold heat insulator to the exhaust manifold converter sub-assembly (TWC: Front and Rear Catalyst) with the 4 bolts.
  Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)
INSTALL NO. 4 EXHAUST MANIFOLD HEAT INSULATOR
1. Install the No. 4 exhaust manifold heat insulator to the exhaust manifold converter sub-assembly (TWC: Front and Rear Catalyst) and turbocharger sub-assembly with the 3 bolts.
  Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)
INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
1. Install the No. 1 exhaust manifold heat insulator to the No. 1 heat insulator bracket and exhaust manifold converter sub-assembly (TWC: Front and Rear Catalyst) with the 5 bolts.
  Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)
INSTALL AIR FUEL RATIO SENSOR
Refer to INSTALLATION [08/2015 - ]