Installation [02/2014 - 11/2016]: Procedure

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

1. Temporarily install the exhaust manifold sub-assembly LH (TWC: Front Catalyst) to the cylinder head sub-assembly LH with the 6 nuts.
2. Using a 12 mm deep socket wrench, tighten the 6 nuts in the order shown in the illustration.
   Fig 1: Install Exhaust Manifold Sub-Assembly LH Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Fig 2: No. 2 Manifold Stay Tightening Sequence

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the No. 2 manifold stay to the exhaust manifold sub-assembly LH (TWC: Front Catalyst) and cylinder block sub-assembly with the bolt and nut in the order shown in the illustration.

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

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

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

Refer to PROCEDURE - Step 19

Refer to PROCEDURE - Step 5

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install a new gasket to the front exhaust pipe assembly.
2. Install the front exhaust pipe assembly to the exhaust manifold sub-assembly LH (TWC: Front Catalyst) with the 2 nuts.

   Torque: 56 N*m (571 kgf*cm, 41 ft.*lbf) 

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

   Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf) 

4. Tighten the bolt (A).

   Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf) 

5. Connect the heated oxygen sensor connector.
6. Engage the 3 wire harness clamps.

Refer to PROCEDURE - Step 1

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

1. Using a 12 mm deep socket wrench, install the exhaust manifold sub-assembly RH (TWC: Front Catalyst) with the 6 nuts in the order shown in the illustration.
   Fig 3: Exhaust Manifold Sub-Assembly RH (TWC: Front Catalyst) Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

2. Engage the 2 wire harness clamps.
3. Connect the air fuel ratio sensor (for Bank 1) connector.

1. Install a new EGR inlet gasket and No. 1 EGR pipe to the exhaust manifold sub-assembly RH (TWC: Front Catalyst) with the bolt and 2 nuts.

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

1. Install the manifold stay to the exhaust manifold sub-assembly RH (TWC: Front Catalyst) and hybrid vehicle transaxle assembly with the bolt and nut.

   for bolt 

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

   for nut 

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

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Minimum

   41.5 mm (1.63 in.)

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

2. Temporarily install a new 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 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	Gasket
   *a	Wooden Block

   NOTE:

   • Be careful with the installation direction of the gasket.
   • 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 2 new gaskets to the front No. 3 exhaust pipe sub-assembly (front exhaust pipe assembly and exhaust manifold sub-assembly RH (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: 56 N*m (571 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	Front No. 3 Exhaust Pipe Sub-assembly
   *2	Center Exhaust Pipe Assembly (TWC: Rear Catalyst)
   *3	Gasket
   *a	Space between Flanges: 8.5 mm (0.335 in.)

8. Connect the heated oxygen sensor (for Bank 1) connector.
9. Engage the 2 wire harness clamps.

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   	Bolt
   	Screw

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

Refer to PROCEDURE - Step 77 , or refer to PROCEDURE - Step 76

Refer to INSTALLATION [02/2014 - 11/2016]

Refer to INSTALLATION [02/2014 - 11/2016]

See step  14