Installation [10/2018 - ]: Procedure

1. Install the No. 2 exhaust manifold heat insulator to the exhaust manifold (TWC: Front Catalyst) with the 3 bolts.

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

1. Install a new exhaust manifold to head gasket to the cylinder head sub-assembly.
2. Temporarily install the exhaust manifold (TWC: Front Catalyst) and No. 1 exhaust manifold 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) Nut Installation Sequence

   Courtesy 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) 

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 Bolt And Nut Tightening Sequence

   Courtesy 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) 

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 3 bolts.

   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 [10/2018 - 07/2022] , or refer to PRECAUTION [07/2022 - ]

   • 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)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Torque Wrench Fulcrum Length

1. Install the No. 1 front floor heat insulator to the vehicle body with the 3 nuts.

   Torque: 5.0 N.m (51 kgf/cm, 44 in.lbf) 

1. Install the wire harness clamp bracket with the bolt.

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

Refer to INSTALLATION [10/2018 - ]

1. Using a vernier caliper, measure the free length of the compression springs.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Minimum Free Length (Front)	41.5 mm (1.63 in.)
   Minimum Free Length (Rear)	38.5 mm (1.52 in.)

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

2. Temporarily install 2 new exhaust pipe gaskets to the exhaust manifold (TWC: Front Catalyst) and front exhaust pipe assembly (TWC: Rear Catalyst).
3. Using a plastic hammer and wooden block, tap in each exhaust pipe gasket until its surface is flush with the exhaust manifold (TWC: Front Catalyst) and front exhaust pipe assembly (TWC: Rear Catalyst).
   NOTE:

   • Be sure to install the exhaust pipe gasket in the correct direction.
   • Do not reuse the exhaust pipe gaskets.
   • Do not damage the exhaust pipe gaskets.
   • Do not push in the exhaust pipe gaskets by using the exhaust pipes when connecting them.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Exhaust Manifold (TWC: Front Catalyst) or Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
   *2	Exhaust Pipe Gasket
   *a	Wooden Block

4. Connect the front exhaust pipe assembly (TWC: Rear Catalyst) to the 2 exhaust pipe supports.
5. Install the front exhaust pipe assembly (TWC: Rear Catalyst) to the exhaust manifold (TWC: Front Catalyst) with the 2 compression springs and 2 bolts.

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

   HINT: 

   After installation, check that the space between the flanges of the exhaust manifold (TWC: Front Catalyst) and front exhaust pipe assembly (TWC: Rear Catalyst) is consistent front-to-rear and left-to-right.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Exhaust Manifold (TWC: Front Catalyst)
   *2	Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
   *3	Exhaust Pipe Gasket
   *a	Space between Flanges: 8.5 mm (0.335 in.)

6. Install the front exhaust pipe assembly (TWC: Rear Catalyst) to the tail exhaust pipe assembly with the 2 compression springs and 2 bolts.

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

   HINT: 

   After installation, check that the space between the flanges of the front exhaust pipe assembly (TWC: Rear Catalyst) and tail exhaust pipe assembly is consistent front-to-rear and left-to-right.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
   *2	Tail Exhaust Pipe Assembly
   *3	Exhaust Pipe Gasket
   *a	Space between Flanges: 6.5 mm (0.256 in.)

7. Engage the clamp.
8. Connect the No. 2 air fuel ratio sensor connector.

See step  4

See step  5

HINT: 

Perform the same procedure as for the front floor cover LH.

See step  7

Refer to PROCEDURE - Step 67 [10/2018 - 07/2022] , or refer to PROCEDURE - Step 67 [07/2022 - ]