Installation [11/2015 - 06/2017]: Procedure

Refer to PROCEDURE - Step 1

1. Install the No. 2 exhaust manifold heat insulator with the 3 bolts.

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

1. Set a new gasket to the cylinder head sub-assembly.
2. Temporarily install the exhaust manifold with the 3 bolts and 2 nuts.
3. Temporarily install the manifold support bracket with the 3 bolts.
4. Tighten the exhaust manifold with the 3 bolts and 2 nuts.

   Courtesy 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.

1. Install a new gasket and No. 1 EGR pipe with the bolt and nut.

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

1. Install the manifold support bracket with the 4 bolts.

   Courtesy 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) 

1. Install the No. 1 exhaust manifold heat insulator with the 3 bolts.

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

Refer to PROCEDURE - Step 1

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002.

   Minimum (front)	41.5 mm (1.64 in.)
   Minimum (rear)	38.5 mm (1.52 in.)

   HINT: 

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

2. Fully insert 2 new gaskets to the exhaust manifold converter and front exhaust pipe assembly.
3. Using a plastic hammer and wooden block, tap in each new gasket until its surface is flush with the exhaust manifold and front exhaust pipe assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002.

   TEXT IN ILLUSTRATION
   
   

   *1	Exhaust Manifold and Front Exhaust Pipe Assembly
   *2	Gasket
   *3	Wooden Block

   NOTE:

   • Be careful with the installation direction of the gaskets.
   • Do not reuse the gaskets.
   • Do not damage the gaskets.
   • Do not push in the gaskets by using the exhaust pipe when connecting it.
4. Connect the front exhaust pipe assembly to the 3 exhaust pipe supports.
5. Install the front 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 gaps between the flanges of the exhaust manifold and front exhaust pipe assembly are consistent front-to-rear and left-to-right.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002.

   TEXT IN ILLUSTRATION
   
   

   *1	Exhaust Manifold
   *2	Front Exhaust Pipe Assembly
   *3	Gasket
   *a	Space between flanges: 8.5 mm (0.335 in.)

6. Install the front 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 gaps between the flanges of the tail exhaust pipe assembly and front exhaust pipe assembly are consistent front-to-rear and left-to-right.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002.

   TEXT IN ILLUSTRATION
   
   

   *1	Tail Exhaust Pipe Assembly
   *2	Front Exhaust Pipe Assembly
   *3	Gasket
   *a	Space between flanges: 6.5 mm (0.256 in.)

7. Connect the 2 heater water hoses.

(Refer to INSTALLATION [11/2015 - ]