Installation [08/2015 - ]: Procedure

Refer to PROCEDURE - Step 2

Refer to PROCEDURE - Step 1

1. Install a new gasket to the cylinder head and a new gasket to the No. 3 air tube.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   TEXT IN ILLUSTRATION
   
   

   *a	Claw
   *b	Tab

   HINT: 

   • Install the exhaust manifold gasket with the gasket tab facing toward the front of the engine.
   • Install the air tube gasket with the claws of the gasket facing the tube.
2. Temporarily install the exhaust manifold assembly RH with 9 new nuts.
3. Temporarily install the manifold stay with the 3 bolts.
4. Tighten the 3 bolts in the sequence shown in the illustration.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 

5. Uniformly tighten the 7 nuts that are not labeled A. Then tighten the 2 nuts labeled A in the illustration.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   for nut A 

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

   except nut A 

   Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

6. Connect the air fuel ratio sensor connector.

   HINT: 

   Hook the wire harness to the bracket.

1. Install the No. 1 exhaust manifold heat insulator with the 3 bolts.

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

1. Install a new gasket to the cylinder head and a new gasket to the No. 4 air tube.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   TEXT IN ILLUSTRATION
   
   

   *a	Claw
   *b	Tab

   HINT: 

   • Install the exhaust manifold gasket with the gasket tab facing toward the rear of the engine.
   • Install the air tube gasket with the claws of the gasket facing the tube.
2. Temporarily install the exhaust manifold assembly LH with 9 new nuts.
3. Temporarily install the No. 2 manifold stay with the 3 bolts.
4. Tighten the 3 bolts in the sequence shown in the illustration.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 

5. Uniformly tighten the 7 nuts that are not labeled A. Then tighten the 2 nuts labeled A in the illustration.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   for nut A 

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

   except nut A 

   Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

6. Connect the air fuel ratio sensor connector.

   HINT: 

   Hook the wire harness to the bracket.

1. Install the No. 2 exhaust manifold heat insulator with the 3 bolts.

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

1. Install 2 new gaskets to the EGR cooler assembly and exhaust manifold assembly LH.
2. Install the No. 1 EGR pipe sub-assembly with 4 new nuts and tighten the nuts in the sequence shown in the illustration.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

Refer to PROCEDURE - Step 1

Refer to PROCEDURE - Step 2

1. Using a plastic-faced hammer and wooden block, tap in a new gasket until its surface is flush with the front exhaust pipe assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   TEXT IN ILLUSTRATION
   
   

   *a	Gasket
   *b	Wooden Block

   NOTE:

   • Be sure to install the gasket so that it faces the correct direction.
   • Do not reuse the gasket.
   • Do not damage the gasket.
   • When connecting the front exhaust pipe assembly, do not push in the gasket with the front exhaust pipe assembly.
2. Install a new gasket and the front exhaust pipe to the exhaust manifold assembly RH with 2 new nuts.

   Torque: 54 N*m (554 kgf*cm, 40 ft.*lbf) 

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Minimum free length

   42 mm (1.65 in.)

   1. If the free length is less than the minimum, replace the compression spring.
4. Connect the front exhaust pipe assembly to the center exhaust pipe with the 2 compression springs and 2 bolts.

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

5. Connect the heated oxygen sensor connector.

   HINT: 

   Hook the wire harness to the bracket.

1. Install 2 new gaskets and the front No. 2 exhaust pipe assembly to the exhaust manifold assembly LH with 2 new nuts.

   Torque: 54 N*m (554 kgf*cm, 40 ft.*lbf) 

2. Connect the front No. 2 exhaust pipe assembly to the front exhaust pipe assembly with the 2 bolts.

   Torque: 48 N*m (489 kgf*cm, 35 ft.*lbf) 

3. Connect the front No. 2 exhaust pipe assembly to the exhaust pipe support.
4. Connect the heated oxygen sensor connector.

1. Install the exhaust pipe stopper bracket with the 2 bolts.

   Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) 

Refer to PROCEDURE - Step 2 [08/2015 - 08/2020] , or refer to PROCEDURE - Step 2 [08/2020 - ]

(Refer to INSTALLATION [08/2015 - ] )

1. Apply a light coat of engine oil to a new O-ring.
2. Install the O-ring to the engine oil level dipstick guide.
3. Install the engine oil level dipstick guide with the bolt.

   Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

4. Install the engine oil level dipstick.

(Refer to INSTALLATION [08/2015 - ] )

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

HINT: 

If an exhaust gas leak has been repaired, perform an inspection following the repair (Refer to INITIALIZATION [08/2015 - ] ).

Refer to PROCEDURE - Step 85 [08/2015 - 08/2020] , or refer to PROCEDURE - Step 85 [08/2020 - ]

Refer to PROCEDURE - Step 84 [08/2015 - 08/2020] , or refer to PROCEDURE - Step 84 [08/2020 - ]

Refer to PROCEDURE - Step 83 [08/2015 - 08/2020] , or refer to PROCEDURE - Step 83 [08/2020 - ]

Refer to PROCEDURE - Step 82 [08/2015 - 08/2020] , or refer to PROCEDURE - Step 82 [08/2020 - ]

Refer to PROCEDURE - Step 86 [08/2015 - 08/2020] , or refer to PROCEDURE - Step 86 [08/2020 - ]

Refer to PROCEDURE - Step 88 [08/2015 - 08/2020] , or refer to PROCEDURE - Step 88 [08/2020 - ]

Refer to PROCEDURE - Step 89 [08/2015 - 08/2020] , or refer to PROCEDURE - Step 89 [08/2020 - ]