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Installation [11/2016 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. INSTALL STUD BOLT 

    HINT: 

    If a stud bolt is deformed or the threads are damaged, replace it.

    1. Using an E8 "TORX" socket wrench, install the 2 stud bolts (A) to the exhaust manifold (TWC: Front Catalyst).
      GTY671582Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 19.5 N*m (199 kgf*cm, 14 ft.*lbf) 

    2. Using an E6 "TORX" socket wrench, install the 2 stud bolts (B) to the exhaust manifold (TWC: Front Catalyst).

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

    3. Using an E8 "TORX" socket wrench, install the 2 stud bolts to the exhaust manifold assembly LH (TWC: Front Catalyst).
      GTY627947Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 19.5 N*m (199 kgf*cm, 14 ft.*lbf) 

  2. INSTALL EXHAUST MANIFOLD TO HEAD GASKET (for Bank 2) 
    1. Install a new exhaust manifold to head gasket (for Bank 2) to the cylinder head sub-assembly LH.
  3. INSTALL EXHAUST MANIFOLD ASSEMBLY LH (TWC: Front Catalyst) 
    1. Temporarily install the exhaust manifold assembly LH (TWC: Front Catalyst) to the cylinder head sub-assembly LH with the 4 nuts.
    2. Temporarily install the No. 2 manifold stay to the exhaust manifold assembly LH (TWC: Front Catalyst) and cylinder block sub-assembly with the bolt and nut.
    3. Using a 12 mm deep socket wrench, tighten the 4 nuts in the order shown in the illustration.
      Fig 1: Exhaust Manifold Assembly LH (TWC: Front Catalyst) Tightening Sequence
      GTY696453Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    4. Tighten the bolt and nut in the order shown in the illustration.
      Fig 2: No. 2 Manfiold Stay Tightening Sequence
      GTY656743Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut

      Nut 

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

      Bolt 

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

  4. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Temporarily install the No. 2 exhaust manifold heat insulator to the exhaust manifold assembly LH (TWC: Front Catalyst) with the 3 bolts.
    2. Tighten the 3 bolts in the order shown in the illustration.

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

      Fig 3: No.2 Exhaust Manifold Heat Insulator Tightening Sequence
      GTY691105Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL AIR FUEL RATIO SENSOR (for Bank 2) 

    Refer to PROCEDURE - Step 4

  6. INSTALL NO. 1 ENGINE COVER 

    Refer to PROCEDURE - Step 5

  7. INSTALL FRONT EXHAUST PIPE ASSEMBLY 

    See step  2

  8. INSTALL EXHAUST MANIFOLD TO HEAD GASKET (for Bank 1) 
    1. Install a new exhaust manifold to head gasket (for Bank 1) to the cylinder head sub-assembly RH.
  9. INSTALL EXHAUST MANIFOLD (TWC: Front Catalyst) 
    1. Temporarily install the exhaust manifold (TWC: Front Catalyst) to the cylinder head sub-assembly RH with the 4 nuts.
    2. Temporarily install the manifold stay to the exhaust manifold (TWC: Front Catalyst) and rear engine mounting bracket with the bolt and nut.
    3. Using a 12 mm deep socket wrench, tighten the 4 nuts in the order shown in the illustration.
      Fig 4: Exhaust Manifold (TWC: Front Catalyst) Tightening Sequence
      GTY633084Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    4. Tighten the bolt and nut in the order shown in the illustration.
      Fig 5: No. 2 Manifold Stay Tightening Sequence
      GTY696662Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut

      Bolt 

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

      Nut 

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

  10. INSTALL AIR FUEL RATIO SENSOR (for Bank 1) 

    Refer to PROCEDURE - Step 1

  11. INSTALL NO. 2 EGR PIPE GASKET 

    See step  8

  12. INSTALL EGR INLET GASKET 

    Refer to PROCEDURE - Step 2

  13. INSTALL EGR VALVE ASSEMBLY 

    Refer to PROCEDURE - Step 3

  14. CONNECT NO. 6 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 4

  15. CONNECT WATER BY-PASS HOSE ASSEMBLY 

    Refer to PROCEDURE - Step 5

  16. CONNECT WIRE HARNESS 

    Refer to PROCEDURE - Step 6

  17. INSTALL RESERVOIR BRACKET 

    Refer to PROCEDURE - Step 41

  18. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY 

    Refer to PROCEDURE - Step 42

  19. INSTALL FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY 
    1. Using a vernier caliper, measure the free length of the 2 compression springs.
      GTY146446Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Standard Length 43.0 mm (1.69 in.)
      Minimum Free Length 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.
      GTY442825Courtesy 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 pipes when connecting them.
    4. Install 2 new gaskets to the front No. 3 exhaust pipe sub-assembly (front exhaust pipe assembly and exhaust manifold (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: 43 N*m (438 kgf*cm, 32 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.

      GTY447370Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Center Exhaust Pipe Assembly (TWC: Rear Catalyst)
      *2 Front No. 3 Exhaust Pipe Sub-assembly
      *3 Gasket
      *a Space between Flanges: 8.5 mm (0.335 in.)
    8. Engage the 2 wire harness clamps.
    9. Connect the heated oxygen sensor (for Bank 1) connector.
  20. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 10

  21. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to INSTALLATION [02/2014 - ]

  22. ADD ENGINE COOLANT (for Engine) 

    Refer to PROCEDURE - Step 2

  23. INSPECT FOR COOLANT LEAK (for Engine) 

    Refer to PROCEDURE - Step 3

  24. INSPECT FOR EXHAUST GAS LEAK 

    See step  10

  25. INSTALL V-BANK COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 74

  26. INSTALL FRONT FLOOR COVER LH 
    1. Install the front floor cover LH with the 2 clips (B).
      GTY454210Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Screw
    2. Install the clip (A), 2 screws and 4 bolts to the front floor cover LH.
  27. INSTALL NO. 2 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 83

  28. INSTALL NO. 1 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 84

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