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Installation [06/2018 - ]: Procedure

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  1. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Type A:
      1. Install the No. 2 exhaust manifold heat insulator to the exhaust manifold (TWC: Front Catalyst) with the 6 bolts.

        Torque: 11 N.m (112 kgf/cm, 8 ft.lbf) 

    2. Type B:
      1. Install the No. 2 exhaust manifold heat insulator to the exhaust manifold with the 3 bolts.

        Torque: 11 N.m (112 kgf/cm, 8 ft.lbf) 

  2. INSTALL EXHAUST MANIFOLD (TWC: Front Catalyst) 
    1. Install a new exhaust manifold to head gasket to the cylinder head sub-assembly.
    2. Temporarily install the exhaust manifold (TWC: Front Catalyst), No. 1 exhaust manifold heat insulator and No. 1 upper front floor heat insulator.

      HINT: 

      At this time, do not install the parts with bolts or nuts.

    3. Using a 12 mm deep socket wrench, temporarily install the exhaust manifold (TWC: Front Catalyst) to the cylinder head sub-assembly with 7 new nuts.
      Fig 1: Exhaust Manifold (TWC: Front Catalyst) Nuts With Tightening Sequence
      GTY741917Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using the 12 mm deep socket wrench, tighten the 7 nuts in the order shown in the illustration.

      Torque: 26 N.m (265 kgf/cm, 19 ft.lbf) 

  3. INSTALL MANIFOLD STAY 
    1. Temporarily install the manifold stay to the exhaust manifold (TWC: Front Catalyst) and cylinder block sub-assembly with the bolt and nut.
      Fig 2: Manifold Stay Tightening Sequence
      GTY768521Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Tighten the bolt and nut in the order shown in the illustration.

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

  4. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Type A:
      1. Using a 10 mm union nut wrench, install the No. 1 exhaust manifold heat insulator to the exhaust manifold (TWC: Front Catalyst) with the 5 bolts.
        GTY769035Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Torque Wrench Fulcrum Length

        Specified tightening torque 

        Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

        HINT: 

        • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

          Refer to PRECAUTION [06/2018 - ]

        • When using a 10 mm union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)): 8.8 N.m (90 kgf/cm, 78 in.lbf)
    2. Type B:
      1. Install the No. 1 exhaust manifold heat insulator to the exhaust manifold with the 3 bolts.

        Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

  5. INSTALL NO. 1 UPPER FRONT FLOOR HEAT INSULATOR 
    1. Using a 10 mm union nut wrench, install the No. 1 upper front floor heat insulator to the vehicle body with the 2 nuts.

      Specified tightening torque 

      Torque: 4.9 N.m (50 kgf/cm, 43 in.lbf) 

      HINT: 

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Refer to PRECAUTION [06/2018 - ]

      • When using a 10 mm union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)): 4.3 N.m (44 kgf/cm, 38 in.lbf)
      GTY743910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Torque Wrench Fulcrum Length
  6. INSTALL WIRE HARNESS CLAMP BRACKET 
    1. Install the wire harness clamp bracket with the bolt.

      Torque: 13 N.m (133 kgf/cm, 10 ft.lbf) 

  7. INSTALL AIR FUEL RATIO SENSOR (for Sensor 1) 

    Refer to INSTALLATION [06/2018 - ]

  8. INSTALL FRONT CENTER UPPER SUSPENSION BRACE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 15 [06/2018 - 08/2021] , or refer to PROCEDURE - Step 15 [08/2021 - ]

  9. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 

    Refer to INSTALLATION [06/2018 - ]

  10. INSTALL FRONT LOWER NO. 1 FLOOR HEAT INSULATOR 

    Refer to PROCEDURE - Step 5

  11. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst) 
    1. Install 2 new gaskets to the front exhaust pipe assembly (TWC: Rear Catalyst).
    2. Connect the front exhaust pipe assembly (TWC: Rear Catalyst) to the 2 exhaust pipe supports.
    3. Install the front exhaust pipe assembly (TWC: Rear Catalyst) to the exhaust manifold (TWC: Front Catalyst) and center exhaust pipe assembly with 2 new bolts and 2 new nuts.

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

    4. Engage the wire harness clamp.
    5. Connect the air fuel ratio sensor (for sensor 2) connector.
  12. INSTALL CENTER FLOOR CROSSMEMBER BRACE 

    See step  5

  13. INSTALL FRONT CENTER FLOOR BRACE 

    See step  6

  14. INSTALL FRONT FLOOR COVER LH 

    See step  7

  15. INSTALL FRONT FLOOR COVER RH 

    See step  8

  16. INSPECT FOR EXHAUST GAS LEAK 

    See step  9

  17. INSTALL NO. 2 ENGINE UNDER COVER ASSEMBLY 

    Refer to PROCEDURE - Step 42 [06/2018 - 08/2021] , or refer to PROCEDURE - Step 43 [08/2021 - ]

  18. INSTALL NO. 1 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 43 [06/2018 - 08/2021] , or refer to PROCEDURE - Step 44 [08/2021 - ]

  19. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH 

    Refer to PROCEDURE - Step 44 [06/2018 - 08/2021] , or refer to PROCEDURE - Step 45 [08/2021 - ]

  20. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH 

    Refer to PROCEDURE - Step 45 [06/2018 - 08/2021] , or refer to PROCEDURE - Step 46 [08/2021 - ]

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