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Installation [06/2017 - ]: Procedure

  1. INSTALL HEATED OXYGEN SENSOR 

    Refer to PROCEDURE - Step 1

  2. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Install the No. 2 exhaust manifold heat insulator with the 3 bolts.

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

  3. INSTALL EXHAUST MANIFOLD (TWC: Front Catalyst) 
    1. Set a new gasket to the cylinder head sub-assembly.
    2. Temporarily install the exhaust manifold (TWC: Front Catalyst) with the 3 bolts and 2 nuts.
    3. Temporarily install the manifold support bracket with the 3 bolts.
    4. Tighten the 3 bolts and 2 nuts.
      GTY726104Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002.
      TEXT IN ILLUSTRATION

      *1 Bolt
      *2 Nut

      Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 

    5. Connect the wire harness clamp and heated oxygen sensor connector.
    6. Remove the 3 bolts and manifold support bracket.
  4. INSTALL NO. 1 EGR PIPE 
    1. Install a new gasket.
    2. Install the No. 1 EGR pipe with the bolt and nut.

      Torque: 31 N*m (316 kgf*cm, 23 ft.*lbf) 

  5. INSTALL MANIFOLD SUPPORT BRACKET 
    1. Install the manifold support bracket with the 4 bolts.
      GTY705603Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002.

      Bolt A 

      Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf) 

      Bolt B 

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

  6. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Install the No. 1 exhaust manifold heat insulator with the 3 bolts.

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

  7. INSTALL AIR FUEL RATIO SENSOR 

    Refer to PROCEDURE - Step 1

  8. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst) (w/ Exhaust Heat Recirculation System) 
    NOTE:

    When installing the heater water hose, ensure that the exhaust heat recirculation system is filled with coolant. Otherwise, the engine water pump assembly may be damaged.

    1. Using a vernier caliper, measure the free length of the compression springs.
      GTY144965Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002.
      Minimum Free Length (Front) 41.5 mm (1.64 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 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 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 gasket in the correct direction.
      • Do not reuse the gaskets.
      • Do not damage the gaskets.
      • Do not push in the gaskets by using the exhaust pipes when connecting them.
      GTY495003Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002.
      *1 Exhaust Manifold (TWC: Front Catalyst) or Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
      *2 Gasket
      *a Wooden Block
    4. Connect the front exhaust pipe assembly (TWC: Rear Catalyst) to the 3 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.

      GTY494377Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002.
      *1 Exhaust Manifold (TWC: Front Catalyst)
      *2 Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
      *3 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.

      GTY757638Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002.
      *1 Tail Exhaust Pipe Assembly
      *2 Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
      *3 Gasket
      *a Space between Flanges: 6.5 mm (0.256 in.)
    7. Connect the 2 heater water hoses and slide the 2 clips to secure them.
  9. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst) (w/o Exhaust Heat Recirculation System) 
    1. Using a vernier caliper, measure the free length of the compression springs.
      GTY144965Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002.
      Minimum Free Length (Front) 41.5 mm (1.64 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 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 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 gasket in the correct direction.
      • Do not reuse the gaskets.
      • Do not damage the gaskets.
      • Do not push in the gaskets by using the exhaust pipes when connecting them.
      GTY495003Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002.
      *1 Exhaust Manifold (TWC: Front Catalyst) or Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
      *2 Gasket
      *a Wooden Block
    4. Connect the front exhaust pipe assembly (TWC: Rear Catalyst) to the 3 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.

      GTY494377Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002.
      *1 Exhaust Manifold (TWC: Front Catalyst)
      *2 Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
      *3 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.

      GTY757638Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002.
      *1 Tail Exhaust Pipe Assembly
      *2 Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
      *3 Gasket
      *a Space between Flanges: 6.5 mm (0.256 in.)
  10. INSTALL EGR COOLER ASSEMBLY 

    Refer to INSTALLATION [11/2015 - ]

  11. INSPECT FOR EXHAUST GAS LEAK 
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