Installation [12/2018 -]: Procedure

1. Install the No. 2 exhaust manifold heat insulator to the exhaust manifold (TWC: Front Catalyst) with the 4 bolts.

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

1. Install a new exhaust manifold to head gasket and a new EGR cooler gasket to the cylinder head sub-assembly.
2. Temporarily install the exhaust manifold (TWC: Front Catalyst) to the cylinder head sub-assembly with 7 new nuts.
3. Temporarily install the manifold stay to the exhaust manifold (TWC: Front Catalyst) and cylinder block sub-assembly with the 3 bolts.
4. Using a 12 mm deep socket wrench, tighten the 7 nuts in the order shown in the illustration.
   Fig 1: Exhaust Manifold (TWC: Front Catalyst) Tightening Sequence (1 Of 2)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) 

5. Tighten the 3 bolts in the order shown in the illustration.
   Fig 2: Exhaust Manifold (TWC: Front Catalyst) Tightening Sequence (2 Of 2)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

6. Engage the clamp.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   	Connect
   	Lock

7. Connect the brake booster pump assembly connector and lock the lock lever as shown in the illustration.
   NOTE:

   • Make sure that the connector is locked securely.
   • Make sure that the connector can be connected smoothly. Do not allow water, oil or dirt to enter.
8. w/ Exhaust Heat Recirculation System:
   1. Connect the engine coolant temperature sensor connector.
   2. Connect the water pipe and hose sub-assembly A to the bracket with the nut.

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

1. Install the No. 1 exhaust manifold heat insulator to the exhaust manifold (TWC: Front Catalyst) with the 6 bolts.

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

1. Install the wiring harness clamp bracket to the cylinder head sub-assembly with the bolt and engage the clamp.

   Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf) 

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Minimum Free Length (Front)	41.5 mm (1.63 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 exhaust pipe 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 exhaust pipe gasket until its surface is flush with the exhaust manifold (TWC: Front Catalyst) and front exhaust pipe assembly (TWC: Rear Catalyst).

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Exhaust Manifold (TWC: Front Catalyst) or Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
   *2	Exhaust Pipe Gasket
   *a	Wooden Block

   NOTE:

   • Be sure to install the exhaust pipe gasket in the correct direction.
   • Do not reuse the exhaust pipe gaskets.
   • Do not damage the exhaust pipe gaskets.
   • Do not push in the exhaust pipe gaskets by using the exhaust pipes when connecting them.
4. Connect the front exhaust pipe assembly (TWC: Rear Catalyst) to the 2 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.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Exhaust Manifold (TWC: Front Catalyst)
   *2	Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
   *3	Exhaust Pipe 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.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

7. Engage the wire harness clamp.
8. Connect the heated oxygen sensor connector.
9. w/ Exhaust Heat Recirculation System:
   1. Connect the outlet heater water hose B and outlet heater water hose C to the No. 2 outlet water pipe and inlet water pipe and slide the 2 clips to secure them.
      NOTE:

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

Refer to INSTALLATION [11/2015 -]

Refer to PROCEDURE - Step 3 [08/2016 - 07/2020] , or refer to PROCEDURE - Step 3 [07/2020 -]

Refer to PROCEDURE - Step 4 [08/2016 - 07/2020] , or refer to PROCEDURE - Step 4 [07/2020 -]

See step  6

1. for Type A:
   1. Install the 3 front center floor braces to the vehicle body with the 12 bolts.

      Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 

2. for Type B:
   1. Install the 2 front center floor braces to the vehicle body with the 8 bolts.

      Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 

1. Engage the 6 clamps to install the front floor cover LH to the vehicle body with the 2 bolts and 3 clips.

   Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

HINT: 

Perform the same procedure as for the front floor cover LH.

Refer to PROCEDURE - Step 63 [12/2018 - 07/2020] , or refer to PROCEDURE - Step 63 [07/2020 -]

Refer to PROCEDURE - Step 66 [12/2018 - 07/2020] , or refer to PROCEDURE - Step 66 [07/2020 -]

Refer to PROCEDURE - Step 64 [12/2018 - 07/2020] , or refer to PROCEDURE - Step 64 [07/2020 -]