Installation [08/2023 - ]: Procedure

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INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
Torque: 11 N.m (112 kgf/cm, 8 ft.lbf)
INSTALL EXHAUST MANIFOLD TO HEAD GASKET

INSTALL EXHAUST MANIFOLD

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*A	for PHEV Model	*B	for HEV Model
*1	Exhaust Manifold	*2	No. 1 Exhaust Manifold Heat Insulator
*3	No. 1 Front Floor Heat Insulator	-	-

Temporarily install the exhaust manifold, No. 1 exhaust manifold heat insulator and No. 1 front floor heat insulator.
HINT:

At this time, do not install the parts with the bolts or nuts.
Temporarily install the exhaust manifold to the cylinder head sub-assembly with 7 new nuts.
Tighten the 7 nuts in the order shown in the illustration.
Torque: 26 N.m (265 kgf/cm, 19 ft.lbf)

INSTALL MANIFOLD STAY

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Temporarily install the manifold stay to the exhaust manifold and cylinder block sub-assembly with the bolt and nut.
Tighten the bolt and nut in the order shown in the illustration.
Torque: 43 N.m (438 kgf/cm, 32 ft.lbf)

INSTALL NO. 1 FRONT FLOOR HEAT INSULATOR

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*A	for PHEV Model	*B	for HEV Model
*a	Torque Wrench Fulcrum Length	-	-

Using a 10 mm union nut wrench, install the No. 1 front floor heat insulator to the vehicle body with the 2 nuts.
Specified tightening torque

Torque: 4.9 N.m (50 kgf/cm, 43 in.lbf)

HINT:
- Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
  Refer to PRECAUTION [10/2022 - ]
- 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.)): 4.3 N.m (44 kgf/cm, 38 in.lbf).

INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

Torque Wrench Fulcrum Length

Using a 10 mm union nut wrench, install the No. 1 exhaust manifold heat insulator to the exhaust manifold 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 [10/2022 - ]
- 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).

INSTALL WIRING HARNESS CLAMP BRACKET
Torque: 13 N.m (133 kgf/cm, 10 ft.lbf)

CONNECT LIQUID TUBE SUB-ASSEMBLY A w/ DISCHARGE TUBE (for PHEV Model)

Remove the vinyl tape, and sufficiently apply compressor oil to a new O-ring and the fitting surface of the liquid tube sub-assembly A.
Compressor Oil

ND-OIL 11 or equivalent
Install the O-ring to the liquid tube sub-assembly A w/ discharge tube.
NOTE:
Keep the O-ring and O-ring fitting surface free from foreign matter.
Connect the liquid tube sub-assembly A w/ discharge tube with the 2 bolts.
Torque

9.8 N.m (100 kgf/cm, 87 in.lbf)

INSTALL HEATER AND ACCESSORY SUB-ASSEMBLY (for PHEV Model)

Refer to PROCEDURE - Step 3
INSTALL AIR FUEL RATIO SENSOR (for Sensor 1)
Refer to INSTALLATION [08/2023 - ]
INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for HEV Model)
Refer to PROCEDURE - Step 18
INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (for HEV Model)
Refer to INSTALLATION [10/2022 - ]
INSTALL FRONT EXHAUST PIPE ASSEMBLY

See step 1
ADD ENGINE COOLANT (for Engine [for HEV Model])
Refer to PROCEDURE - Step 5
INSPECT FOR COOLANT LEAK (for Engine [for HEV Model])
Refer to PROCEDURE - Step 1
INSPECT FOR EXHAUST GAS LEAK
1. If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.
  HINT:
  
  Perform "Inspection After Repairs" after repairing or replacing the exhaust system.
  
  Refer to INITIALIZATION [10/2022 - ]
INSTALL ENGINE UNDER COVER HEAT INSULATOR (for PHEV Model)

Refer to PROCEDURE - Step 10
INSTALL FRONT FLOOR COVER LH
- for PHEV Model:
  Refer to PROCEDURE - Step 31
- for HEV Model:
  Refer to PROCEDURE - Step 19
INSTALL NO. 2 ENGINE UNDER COVER ASSEMBLY
Refer to PROCEDURE - Step 6