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Installation [11/2016 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. INSTALL HEATED OXYGEN SENSOR (for Bank 2) 

    Refer to PROCEDURE - Step 1

  2. INSTALL FRONT EXHAUST PIPE ASSEMBLY 
    1. Install a new gasket to the front exhaust pipe assembly.
      GTY725356Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    2. Install the front exhaust pipe assembly to the exhaust manifold assembly LH (TWC: Front Catalyst) with 2 new nuts.

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

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

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

    4. Tighten the bolt (A).

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

    5. Connect the heated oxygen sensor connector.
    6. Engage the wire harness clamp.
  3. INSTALL FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY 
    1. Install 2 new gaskets to the front No. 3 exhaust pipe sub-assembly.
    2. Install the front No. 3 exhaust pipe sub-assembly to the front exhaust pipe assembly and exhaust manifold (TWC: Front Catalyst) with 2 new bolts and 2 new nuts.

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

  4. INSTALL HEATED OXYGEN SENSOR (for Bank 1) 

    Refer to PROCEDURE - Step 5

  5. INSTALL CENTER EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst) 
    1. Using a vernier caliper, measure the free length of the 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.
    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. Connect the center exhaust pipe assembly (TWC: Rear Catalyst) to the 5 exhaust pipe supports.
    5. Install the center exhaust pipe assembly (TWC: Rear Catalyst) to the front No. 3 exhaust pipe sub-assembly with 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.)
    6. Connect the 2 heater water hoses to the center exhaust pipe assembly (TWC: Rear Catalyst) and 2 clips secure them.
  6. INSTALL HEATER COVER 
    1. Install the heater cover to the water hose bracket and vehicle body with the 3 bolts.

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

    2. Engage the clamp.
  7. INSTALL TAIL EXHAUST PIPE ASSEMBLY 
    1. Using a vernier caliper, measure the free length of the 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 center exhaust pipe assembly (TWC: Rear Catalyst).
    3. Using a plastic hammer and wooden block, tap in the gasket until its surface is flush with the center exhaust pipe assembly (TWC: Rear Catalyst).
      GTY442825Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Center Exhaust Pipe Assembly (TWC: Rear Catalyst)
      *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. Connect the tail exhaust pipe assembly to the exhaust pipe support.
    5. Install the tail exhaust pipe assembly to the center exhaust pipe assembly (TWC: Rear Catalyst) with 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 tail exhaust pipe assembly and center exhaust pipe assembly (TWC: Rear Catalyst) is consistent front-to-rear and left-to-right.

      GTY447370Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Tail Exhaust Pipe Assembly
      *2 Center Exhaust Pipe Assembly (TWC: Rear Catalyst)
      *3 Gasket
      *a Space between Flanges: 8.5 mm (0.335 in.)
  8. ADD ENGINE COOLANT (for Engine) 

    Refer to PROCEDURE - Step 2

  9. INSPECT FOR COOLANT LEAK (for Engine) 

    Refer to PROCEDURE - Step 3

  10. INSPECT FOR EXHAUST GAS LEAK 

    If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.

    1. Perform Inspection After Repair after repairing an exhaust gas leak.

      Refer to INITIALIZATION [11/2016 - ]

  11. INSTALL FRONT FLOOR COVER LH 

    See step  26

  12. INSTALL NO. 2 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 83

  13. INSTALL NO. 1 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 84

  14. INSTALL V-BANK COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 74

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