Installation [09/2015 - ]: Procedure

HINT: 

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

1. Using an E8 "TORX" socket wrench, install the 2 stud bolts to the exhaust manifold (TWC: Front Catalyst).

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

2. Using an E8 "TORX" socket wrench, install the 2 stud bolts to the exhaust manifold assembly LH (TWC: Front Catalyst).

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

1. Install a new exhaust manifold to head gasket to the cylinder head sub-assembly.

1. Temporarily install the exhaust manifold assembly LH (TWC: Front Catalyst) 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.
   Fig 1: Exhaust Manifold Assembly LH (TWC: Front Catalyst) Tightening Sequence

   Courtesy 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.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   	Bolt
   	Nut

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

5. Connect the No. 1 radiator hose to the radiator assembly and slide the clip to secure it.
6. Connect the 2 No. 2 cooling fan motor connectors.

Refer to PROCEDURE - Step 4

1. Install the No. 2 exhaust manifold heat insulator to the exhaust manifold assembly LH (TWC: Front Catalyst) with the 3 bolts in the order shown in the illustration.

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

   Fig 2: No. 2 Exhaust Manifold Heat Insulator Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Engage the wire harness clamp.
3. Connect the air fuel ratio sensor connector.

Refer to PROCEDURE - Step 40 [09/2015 - 08/2016] , or refer to PROCEDURE - Step 40 [08/2016 - 12/2017] , or refer to PROCEDURE - Step 40 [12/2017 - 08/2019] , or refer to PROCEDURE - Step 40 [08/2019 - ]

Refer to PROCEDURE - Step 8 [09/2015 - 12/2017] , or refer to PROCEDURE - Step 8 [12/2017 - ]

See step  2 [09/2015 - 12/2017], or see step  2 [12/2017 - ]

See step  3 [09/2015 - 12/2017], or see step  3 [12/2017 - ]

1. Install a new exhaust manifold to head gasket to the cylinder head sub-assembly RH.

1. Temporarily install the exhaust manifold (TWC: Front Catalyst) 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.

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

   Fig 3: Exhaust Manifold (TWC: Front Catalyst) Tightening Sequence

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

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   	Bolt
   	Nut

1. Using a vernier caliper, measure the free length of the 2 compression springs.

   Courtesy 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 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.

   Courtesy 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.
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.

   Courtesy 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. Connect the heated oxygen sensor (for Bank 1) connector.
9. Engage the 4 wire harness clamps.

1. Install the front floor cover LH with the 2 clips (B).

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   *A	for TMC Made
   *B	for TMMC Made
   	Bolt
   	Screw

2. Install the clip (A), 2 screws and 4 bolts to the front floor cover LH.

Refer to PROCEDURE - Step 1

Refer to PROCEDURE - Step 66 [09/2015 - 08/2016] , or refer to PROCEDURE - Step 66 [08/2016 - 12/2017] , or refer to PROCEDURE - Step 66 [12/2017 - 08/2019] , or refer to PROCEDURE - Step 66 [08/2019 - ]

Refer to PROCEDURE - Step 2 [09/2015 - 12/2017] , or refer to PROCEDURE - Step 2 [12/2017 - ]

Refer to PROCEDURE - Step 1

See step  9 [09/2015 - 12/2017], or see step  10 [12/2017 - ]