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Installation [12/2013 - 11/2016]: Procedure

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  1. INSTALL EXHAUST MANIFOLD TO HEAD GASKET LH 
    1. Install a new exhaust manifold to head gasket LH to the cylinder head sub-assembly.
  2. INSTALL AIR FUEL RATIO SENSOR (for Bank 1) 

    Refer to PROCEDURE - Step 1

  3. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH (TWC: Front Catalyst) 
    1. Temporarily install the exhaust manifold sub-assembly LH (TWC: Front Catalyst) with the 6 nuts.
    2. Using a 12 mm deep socket wrench, tighten the 6 nuts in the order shown in the illustration.
      Fig 1: Exhaust Manifold Sub-Assembly LH Tighten Sequence
      GTY447304Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  4. INSTALL NO. 2 MANIFOLD STAY 
    1. Install the No. 2 manifold stay to the exhaust manifold sub-assembly LH (TWC: Front Catalyst) and cylinder block sub-assembly with the bolt and nut in the order shown in the illustration.
      Fig 2: No. 2 Manifold Stay Tightening Sequence
      GTY440840Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  5. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Install the No. 2 exhaust manifold heat insulator to the exhaust manifold sub-assembly LH (TWC: Front Catalyst) with the 3 bolts.

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

  6. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE 

    Refer to PROCEDURE - Step 16

  7. INSTALL AIR FUEL RATIO SENSOR (for Bank 2) 

    Refer to PROCEDURE - Step 4

  8. INSTALL FRONT EXHAUST PIPE ASSEMBLY 
    1. Install a new gasket to the front exhaust pipe assembly.
    2. Install the front exhaust pipe assembly to the exhaust manifold sub-assembly LH (TWC: Front Catalyst) with the 2 nuts.

      Torque: 56 N*m (571 kgf*cm, 41 ft.*lbf) 

    3. Connect the heated oxygen sensor (for Bank 2) connector.
    4. Engage the 3 wire harnesses clamps.
  9. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET (for Lower Side) 
    1. Install the No. 1 exhaust pipe support bracket with the 2 bolts.

      Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf) 

  10. INSTALL EXHAUST MANIFOLD TO HEAD GASKET 
    1. Install a new exhaust manifold to head gasket to the cylinder head sub-assembly.
  11. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH (TWC: Front Catalyst) 
    1. Using a 12 mm deep socket wrench, install the exhaust manifold sub-assembly RH (TWC: Front Catalyst) with the 6 nuts.

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

    2. Engage the wire harness clamp.
    3. Connect the air fuel ratio sensor (for Bank 1) connector.
  12. INSTALL MANIFOLD STAY 
    1. Install the manifold stay to the exhaust manifold sub-assembly RH (TWC: Front Catalyst) and automatic transaxle assembly with bolt and nut.

      Bolt 

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

      Nut 

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

  13. INSTALL FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY 
    1. Using a vernier caliper, measure the free length of the compression springs.
      GTY146446Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Minimum 41.5 mm (1.63 in.)

      If the free length is less than 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 pipe when connecting it.
    4. Install 2 new gaskets to the front No. 3 exhaust pipe sub-assembly.
    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: 56 N*m (571 kgf*cm, 41 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.

      GTY447366Courtesy 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. Connect the heated oxygen sensor (for Bank 1) connector.
    9. Engage the 4 wire harness clamps.
  14. TEMPORARILY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 4WD) 

    Refer to PROCEDURE - Step 1

  15. FULLY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 4WD) 

    Refer to PROCEDURE - Step 2

  16. 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.
  17. INSTALL NO. 2 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 95

  18. INSTALL RADIATOR ASSEMBLY 

    Refer to INSTALLATION [12/2013 - 11/2016]

  19. INSPECT FOR EXHAUST GAS LEAK 

    See step  9

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