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Installation [10/2023 - ]: Procedure

  1. INSTALL NO. 2 MANIFOLD CONVERTER INSULATOR 
    1. Exhaust manifold assembly LH side:
      1. Install the No. 2 manifold converter insulator to the exhaust manifold assembly with the 3 bolts.

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

    2. Exhaust manifold assembly RH side:
      1. Install the No. 2 manifold converter insulator to the exhaust manifold assembly with the 4 bolts.

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

  2. INSTALL NO. 1 MANIFOLD CONVERTER INSULATOR 
    1. Install the 2 No. 1 manifold converter insulators to the exhaust manifold assembly with the 8 bolts.

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

  3. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Install the 2 No. 1 exhaust manifold heat insulators to the exhaust manifold assembly with the 6 bolts.

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

  4. INSTALL EXHAUST MANIFOLD ASSEMBLY RH 

    HINT: 

    Perform "Inspection After Repairs" after replacing the air fuel ratio sensor.

    Refer to INITIALIZATION [10/2023 - ]

    1. Using SST, install the air fuel ratio sensor to the exhaust manifold assembly RH.
      • SST: 09224-00012 

      Torque

      Specified tightening torque 

      44 N.m (449 kgf/cm, 32 ft.lbf)

      NOTE:

      Replace with a new part if it is dropped or if it receives a strong impact.

      HINT: 

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

        Refer to PRECAUTION [10/2023 - ]

      • When using SST (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 37.7 N.m (384 kgf/cm, 28 ft.lbf)
      GTY797604Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A Bank 1 Sensor 1 Side
      *B Bank 1 Sensor 2 Side
      *a Torque Wrench Fulcrum Length
    2. Install a new gasket to the cylinder head sub-assembly.
    3. Temporarily install the exhaust manifold assembly RH with 4 new nuts.
    4. Tighten the 4 nuts in the sequence shown in the illustration.
      GTY817101Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  5. INSTALL EXHAUST MANIFOLD ASSEMBLY LH 

    HINT: 

    Perform "Inspection After Repairs" after replacing the air fuel ratio sensor.

    Refer to INITIALIZATION [10/2023 - ]

    1. Using SST, install the air fuel ratio sensor to the exhaust manifold assembly LH.
      • SST: 09224-00012 

      Torque

      Specified tightening torque 

      44 N.m (449 kgf/cm, 32 ft.lbf)

      NOTE:

      Replace with a new part if it is dropped or if it receives a strong impact.

      HINT: 

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

        Refer to PRECAUTION [10/2023 - ]

      • When using SST (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 37.7 N.m (384 kgf/cm, 28 ft.lbf)
      GTY779763Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A Bank 2 Sensor 1 Side
      *B Bank 2 Sensor 2 Side
      *a Torque Wrench Fulcrum Length
    2. Install a new gasket to the cylinder head sub-assembly LH.
    3. Temporarily install the exhaust manifold assembly LH with 4 new nuts.
    4. Tighten the 4 nuts in the sequence shown in the illustration.
      GTY811890Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  6. TEMPORARILY INSTALL FRONT PROPELLER SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 1

  7. TIGHTEN FRONT PROPELLER SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 3

  8. CONNECT AIR FUEL RATIO SENSOR 
    1. for Bank 1 Sensor 1:
      1. Connect the connector.
      2. Attach the 3 wire harness clamps.
    2. for Bank 1 Sensor 2:
      1. Connect the connector.
      2. Attach the 2 wire harness clamps.
    3. for Bank 2 Sensor 1:
      1. Connect the connector.
      2. Attach the 4 wire harness clamps.
    4. for Bank 2 Sensor 2:
      1. Connect the connector.
      2. Attach the 3 wire harness clamps.
  9. INSTALL NO. 1 EGR PIPE 

    Refer to PROCEDURE - Step 5

  10. INSTALL FENDER APRON BRACE SUB-ASSEMBLY RH 

    Refer to PROCEDURE - Step 8

  11. INSTALL FENDER APRON BRACE SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 46

  12. CONNECT GENERATOR CABLE AND MOTOR CABLE 

    Refer to PROCEDURE - Step 13

  13. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY 
    1. Install the No. 1 exhaust pipe support bracket sub-assembly with the 2 bolts.

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

  14. INSTALL FRONT EXHAUST PIPE ASSEMBLY 

    See step  3

  15. INSTALL FRONT CENTER FLOOR BRACE SUB-ASSEMBLY 

    See step  4

  16. INSTALL FLOOR BOARD SUB-ASSEMBLY 

    See step  5

  17. INSTALL NO. 2 FLOOR BOARD SUB-ASSEMBLY 

    See step  6

  18. INSTALL REAR FLOOR SIDE MEMBER COVER RH 

    See step  7

  19. INSTALL REAR FLOOR SIDE MEMBER COVER LH 

    See step  8

  20. INSTALL STRUT BAR BRACKET SUPPORT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 113

  21. INSTALL FRONT SUSPENSION MEMBER BRACE 

    Refer to PROCEDURE - Step 114

  22. INSTALL NO. 2 ENGINE UNDER COVER ASSEMBLY 

    Refer to PROCEDURE - Step 115

  23. INSTALL TRANSMISSION UNDER COVER 

    Refer to PROCEDURE - Step 116

  24. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY 

    Refer to PROCEDURE - Step 117

  25. INSTALL FRONT APRON FENDER INSULATOR LH 
    1. Install the front fender apron insulator LH with the 3 bolts.

      Torque: 5.4 N.m (55 kgf/cm, 48 in.lbf) 

  26. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE 

    Refer to PROCEDURE - Step 20

  27. INSTALL AIR CLEANER WITH AIR CLEANER HOSE 

    Refer to PROCEDURE - Step 4

  28. INSTALL NO. 1 AIR CLEANER INLET 

    Refer to PROCEDURE - Step 5

  29. INSTALL RADIATOR SUPPORT TO CROSSMEMBER BRACE SUB-ASSEMBLY RH 
    1. Install the radiator support to cross member brace sub-assembly RH with the 2 bolts.

      Torque: 49 N.m (500 kgf/cm, 36 ft.lbf) 

  30. INSTALL RADIATOR SUPPORT TO CROSSMEMBER BRACE SUB-ASSEMBLY LH 
    1. Install the radiator support to cross member brace sub-assembly LH with the 2 bolts.

      Torque: 49 N.m (500 kgf/cm, 36 ft.lbf) 

  31. INSTALL LOWER RADIATOR AIR DEFLECTOR 
    1. Attach the 7 clips to install the lower radiator air deflector.
  32. INSTALL UPPER RADIATOR SUPPORT SEAL 
    1. Attach the 7 clips to install the upper radiator support seal.
  33. INSTALL RADIATOR COVER PLATE 
    1. Attach the 7 clips to install the radiator cover plate.
  34. INSTALL V-BANK COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 121

  35. INSPECT FOR EXHAUST GAS LEAK 

    See step  9

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