Installation [10/2014 - ]: Procedure

1. Install the No. 2 exhaust manifold heat insulator to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) with the 2 bolts.

   Torque: 14 N*m (138 kgf*cm, 10 ft.*lbf) 

1. Set a new exhaust manifold gasket to the cylinder head sub-assembly.
2. Temporarily install the exhaust manifold converter sub-assembly (TWC: Front Catalyst) with the 5 nuts.
3. Temporarily install the No. 2 manifold stay and manifold stay with the 2 bolts and 2 nuts.
4. Tighten the 5 nuts in the order shown in the illustration.
   Fig 1: Exhaust Manifold Converter Sub-Assembly Tightening Sequence (TWC: Front Catalyst)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf) 

1. Tighten the bolt and nut in the order shown in the illustration.
   Fig 2: Manifold Stay Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

1. Tighten the bolt and nut in the order shown in the illustration.
   Fig 3: No. 2 Manifold Stay Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

1. Install 2 new No. 2 EGR pipe gaskets to the No. 2 EGR pipe.
2. Install the No. 2 EGR pipe with the 2 bolts and 2 nuts.

   Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) 

1. Install the No. 1 manifold converter insulator to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) with the 3 bolts.

   Torque: 14 N*m (138 kgf*cm, 10 ft.*lbf) 

Refer to PROCEDURE - Step 1

1. Install the No. 1 exhaust manifold heat insulator to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) with the 4 bolts.

   Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard	42.0 mm (1.65 in.)
   Minimum	40.5 mm (1.59 in.)

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

2. Fully install a new gasket to the exhaust manifold converter sub-assembly (TWC: Front Catalyst).
3. Using a plastic hammer and wooden block, tap in the new gasket until its surface is flush with the exhaust manifold converter sub-assembly (TWC: Front Catalyst).

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   TEXT IN ILLUSTRATION
   
   

   *1	Exhaust Manifold Converter Sub-assembly (TWC: Front Catalyst)
   *2	Wooden Block
   *3	Gasket

   NOTE:

   • Be sure to install the gasket in the correct direction.
   • Do not reuse the gasket.
   • Do not damage the gasket.
   • Do not push in the gasket by using the exhaust pipe when connecting it.
4. Install a new gasket to the front exhaust pipe assembly (TWC: Rear Catalyst).
5. Connect the front exhaust pipe assembly (TWC: Rear Catalyst) to the exhaust pipe support.
6. Install the front exhaust pipe assembly (TWC: Rear Catalyst) with the 2 compression springs, 2 bolts and 2 nuts.

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

   HINT: 

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   TEXT IN ILLUSTRATION
   
   

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

7. Connect the heated oxygen sensor connector.