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Installation [10/2015 - ]: Procedure

  1. INSTALL STUD BOLT 

    HINT: 

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

    1. Using an E8 "TORX" socket wrench, install the 2 stud bolts (A) to the exhaust manifold (TWC: Front Catalyst).
      GTY671582Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 19.5 N*m (199 kgf*cm, 14 ft.*lbf) 

    2. Using an E6 "TORX" socket wrench, install the 2 stud bolts (B) to the exhaust manifold (TWC: Front Catalyst).

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

    3. Using an E8 "TORX" socket wrench, install the 2 stud bolts to the exhaust manifold assembly LH (TWC: Front Catalyst).
      GTY627947Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 19.5 N*m (199 kgf*cm, 14 ft.*lbf) 

  2. INSTALL EXHAUST MANIFOLD TO HEAD GASKET (for Bank 2) 
    1. Install a new exhaust manifold to head gasket (for Bank 2) to the cylinder head sub-assembly LH.
  3. INSTALL EXHAUST MANIFOLD ASSEMBLY LH (TWC: Front Catalyst) 
    1. Temporarily install the exhaust manifold assembly LH (TWC: Front Catalyst) to the cylinder head sub-assembly LH with the 4 nuts.
    2. Temporarily install the No. 2 manifold stay to the exhaust manifold assembly LH (TWC: Front Catalyst) and cylinder block sub-assembly with the bolt and nut.
    3. Using a 12 mm deep socket wrench, tighten the 4 nuts in the order shown in the illustration.
      GTY638626Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    4. Tighten the bolt and nut in the order shown in the illustration.
      GTY656743Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut

      Torque: 34 N*m (347 kgf*cm, 25 ft.*lbf) 

  4. INSTALL AIR FUEL RATIO SENSOR (for Bank 2) 

    Refer to PROCEDURE - Step 5

  5. INSTALL NO. 1 ENGINE COVER 
    1. Install the No. 1 engine cover.
    2. Engage the wire harness clamp.
  6. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Temporarily install the No. 2 exhaust manifold heat insulator to the exhaust manifold assembly LH (TWC: Front Catalyst) with the 3 bolts.
    2. Tighten the 3 bolts in the order shown in the illustration.

      Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) 

      Fig 1: No. 2 Exhaust Manifold Heat Insulator Tightening Sequence
      GTY619203Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the air fuel ratio sensor connector.
    4. Engage the wire harness clamp.
  7. INSTALL INLET AIR CLEANER ASSEMBLY 

    Refer to PROCEDURE - Step 6

  8. INSTALL COOL AIR INTAKE DUCT SEAL 

    Refer to PROCEDURE - Step 4 [10/2015 - 08/2016] , or refer to PROCEDURE - Step 4 [08/2016 - 08/2019] , or refer to PROCEDURE - Step 4 [08/2019 - ]

  9. CONNECT NO. 1 RADIATOR HOSE 
    1. Connect the No. 1 radiator hose to the radiator assembly and slide the clip to secure it.
  10. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE 

    Refer to PROCEDURE - Step 31

  11. INSTALL FRONT EXHAUST PIPE ASSEMBLY 
    GTY671320Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Bolt
    Nut
    1. Install a new exhaust pipe gasket to the front exhaust pipe assembly.
    2. Install the front exhaust pipe assembly to the exhaust manifold (TWC: Front Catalyst) with the 2 nuts.

      Torque: 55 N*m (561 kgf*cm, 41 ft.*lbf) 

    3. Install the exhaust pipe support bracket to the front exhaust pipe assembly with the 2 bolts (B).

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

    4. Tighten the bolt (A).

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

    5. Connect the heated oxygen sensor connector.
    6. Engage the wire harness clamp.
  12. INSTALL EXHAUST MANIFOLD TO HEAD GASKET (for Bank 1) 
    1. Install a new exhaust manifold to head gasket (for Bank 1) to the cylinder head sub-assembly RH.
  13. INSTALL EXHAUST MANIFOLD (TWC: Front Catalyst) 
    1. Temporarily install the exhaust manifold (TWC: Front Catalyst) to the cylinder head sub-assembly RH with the 4 nuts.
    2. Temporarily install the manifold stay to the exhaust manifold (TWC: Front Catalyst) and rear engine mounting bracket with the bolt and nut.
    3. Using a 12 mm deep socket wrench, tighten the 4 nuts in the order shown in the illustration.
      GTY633084Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    4. Tighten the bolt and nut in the order shown in the illustration.
      GTY623836Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut

      Torque: 34 N*m (347 kgf*cm, 25 ft.*lbf) 

  14. INSTALL AIR FUEL RATIO SENSOR (for Bank 1) 

    Refer to PROCEDURE - Step 1

  15. INSTALL NO. 2 EGR PIPE GASKET 

    See step  8

  16. INSTALL EGR INLET GASKET 

    Refer to PROCEDURE - Step 2

  17. INSTALL EGR VALVE ASSEMBLY 

    Refer to PROCEDURE - Step 3

  18. CONNECT NO. 6 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 4

  19. CONNECT WATER BY-PASS HOSE ASSEMBLY 

    Refer to PROCEDURE - Step 5

  20. CONNECT WIRE HARNESS 

    Refer to PROCEDURE - Step 6

  21. INSTALL RESERVOIR BRACKET 

    Refer to PROCEDURE - Step 11 [10/2015 - 03/2018] , or refer to PROCEDURE - Step 11 [03/2018 - ]

  22. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY 

    See step  12

  23. INSTALL FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY 
    1. Using a vernier caliper, measure the free length of the 2 compression springs.
      GTY146446Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Standard Length 43.0 mm (1.69 in.)
      Minimum Free Length 41.5 mm (1.63 in.)

      If the free length is less than the minimum, replace the compression spring.

    2. Temporarily install a new exhaust pipe gasket to the front No. 3 exhaust pipe sub-assembly (center exhaust pipe assembly (TWC: Rear Catalyst) side).
    3. Using a plastic hammer and wooden block, tap in the exhaust pipe gasket until its surface is flush with the front No. 3 exhaust pipe sub-assembly.
      GTY442825Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front No. 3 Exhaust Pipe Sub-assembly
      *2 Exhaust Pipe Gasket
      *a Wooden Block
      NOTE:
      • Be careful with the installation direction of the exhaust pipe gasket.
      • Do not reuse the exhaust pipe gasket.
      • Do not damage the exhaust pipe gasket.
      • Do not push in the exhaust pipe gasket by using the exhaust pipes when connecting them.
    4. Install 2 new exhaust pipe gaskets to the front No. 3 exhaust pipe sub-assembly (front exhaust pipe assembly and exhaust manifold (TWC: Front Catalyst) side).
    5. Temporarily install the front No. 3 exhaust pipe sub-assembly with the 4 bolts, 2 nuts and 2 compression springs.
    6. Tighten the 2 bolts and 2 nuts.

      Torque: 55 N*m (561 kgf*cm, 41 ft.*lbf) 

    7. Tighten the 2 bolts and 2 compression springs.

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

      HINT: 

      After installation, check that the space between the flanges of the center exhaust pipe assembly (TWC: Rear Catalyst) and front No. 3 exhaust pipe sub-assembly is consistent front-to-rear and left-to-right.

      GTY447370Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Center Exhaust Pipe Assembly (TWC: Rear Catalyst)
      *2 Front No. 3 Exhaust Pipe Sub-assembly
      *3 Exhaust Pipe Gasket
      *a Space between Flanges: 8.5 mm (0.335 in.)
    8. Engage the 2 wire harness clamps.
    9. Connect the heated oxygen sensor (for Bank 1) connector.
  24. ADD ENGINE COOLANT (for Engine) 

    Refer to PROCEDURE - Step 4 [10/2015 - 03/2018] , or refer to PROCEDURE - Step 4 [03/2018 - ]

  25. INSPECT FOR COOLANT LEAK (for Engine) 

    Refer to PROCEDURE - Step 5 [10/2015 - 03/2018] , or refer to PROCEDURE - Step 5 [03/2018 - ]

  26. INSPECT FOR EXHAUST GAS LEAK 

    See step  [10/2015 - 03/2018], or see step  [03/2018 - ]

  27. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 12 [10/2015 - 08/2016] , or refer to PROCEDURE - Step 12 [08/2016 - 08/2019] , or refer to PROCEDURE - Step 12 [08/2019 - ]

  28. INSTALL FRONT WIPER MOTOR AND LINK ASSEMBLY 

    Refer to INSTALLATION [10/2015 - ]

  29. INSTALL V-BANK COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 87 [10/2015 - 08/2019] , or refer to PROCEDURE - Step 89 [08/2019 - ]

  30. INSTALL NO. 3 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 85 [10/2015 - 08/2019] , or refer to PROCEDURE - Step 87 [08/2019 - ]

  31. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH 

    Refer to PROCEDURE - Step 86 [10/2015 - 08/2019] , or refer to PROCEDURE - Step 88 [08/2019 - ]

  32. INSTALL FRONT FLOOR COVER LH 

    Refer to PROCEDURE - Step 5

  33. INSTALL NO. 2 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 15

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