Installation [08/2016 - ]: Procedure

HINT: 

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

1. Using an E8 "TORX" socket wrench, install the 2 stud bolts to the exhaust manifold sub-assembly RH (TWC: front catalyst).

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

2. Using an E8 "TORX" socket wrench, install the 2 stud bolts to the exhaust manifold sub-assembly LH (TWC: front catalyst).

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install a new exhaust manifold to head gasket to the cylinder head sub-assembly.

1. Temporarily install the exhaust manifold sub-assembly LH with the 4 nuts.
   Fig 1: Exhaust Manifold Sub-Assembly LH Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a 12 mm deep socket wrench, tighten the 4 nuts in the order shown in the illustration.

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

Refer to PROCEDURE - Step 11

1. Install the No. 2 exhaust manifold heat insulator, tightening the 3 bolts in the order shown in the illustration.
   Fig 2: No. 2 Exhaust Manifold Heat Insulator Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

2. Connect the air fuel ratio sensor (for bank 2) connector and engage the 2 harness clamps.

1. Install the No. 2 manifold stay, tightening the bolt and nut in the order shown in the illustration.
   Fig 3: No. 2 Manifold Stay Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Bolt 

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

   Nut 

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

Refer to PROCEDURE - Step 1

1. Install a new exhaust manifold to head gasket.

1. Temporarily install the exhaust manifold sub-assembly RH (TWC: front catalyst) with the 4 nuts.
   Fig 4: Exhaust Manifold Sub-Assembly RH Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a 12 mm deep socket wrench, tighten the 4 nuts in the order shown in the illustration.

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

3. Connect the air fuel ratio sensor (for bank 1) connector and engage the 3 harness clamps.

1. Install the manifold stay with the 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) 

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

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Free Length of Compression Spring

      Standard Length	Minimum Length
      40.36 mm (1.59 in.)	38.86 mm (1.53 in.)

      If the length is not as specified, replace the compression spring.

2. Using a plastic hammer and a wooden block, tap in a new gasket until its surface is flush with the front exhaust pipe assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Gasket
   *2	Front Exhaust Pipe Assembly
   *a	Wooden Block
   *b	Plastic Hammer

   NOTE:

   • Install the gasket in the correct direction.
   • Do not reuse the gasket.
   • Do not damage the gasket by dropping it, etc.
   • Do not damage the outer surface of the gasket.
   • Do not push in the gasket with the center exhaust pipe assembly when connecting it.
3. Install 2 new gaskets to the front exhaust pipe assembly.
4. Install the front exhaust pipe assembly to the exhaust manifold sub-assembly LH (TWC: front catalyst) and exhaust manifold sub-assembly RH (TWC: front catalyst) with 4 new nuts.

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

5. Connect the front exhaust pipe assembly to the center exhaust pipe sub-assembly (TWC: rear catalyst) with the 2 compression springs and 2 bolts.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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

   NOTE:

   After the installation, check that the gaps between the flanges of the front exhaust pipe assembly and center exhaust pipe assembly are consistent front-to-rear and left-to-right.

6. Connect the exhaust pipe clamp to the No. 1 exhaust pipe support bracket and tighten the bolt.

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

7. Engage the 2 clamps to connect the heated oxygen sensor (for bank 2) wire to the wire harness clamp bracket.
8. Connect the heated oxygen sensor (for bank 2) connector.
9. Pass the connector through the hole to the inside of the vehicle and install the grommet of the heated oxygen sensor (for bank 1) wire.
10. Connect the heated oxygen sensor (for bank 1) connector.

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 2 new nuts.

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

3. Inspect the free length.
   1. Using a vernier caliper, measure the free length of the compression spring.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Free Length of Compression Spring

      Standard Length	Minimum Length
      42 mm (1.65 in.)	40.5 mm (1.59 in.)

      If the length is not as specified, replace the compression spring.

4. Using a plastic hammer and a wooden block, tap in a new gasket until its surface is flush with the front No. 3 exhaust pipe sub-assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Gasket
   *2	Exhaust Manifold Converter Sub-assembly
   *a	Wooden Block
   *b	Plastic Hammer

   NOTE:

   • Install the gasket in the correct direction.
   • Do not reuse the gasket.
   • Do not damage the gasket by dropping it, etc.
   • Do not damage the outer surface of the gasket.
   • Do not push in the gasket with the front No. 3 exhaust pipe sub-assembly (TWC: rear catalyst) when connecting it.
5. Install 2 new gaskets to the front No. 3 exhaust pipe sub-assembly.
6. Install the front No. 3 exhaust pipe sub-assembly to the exhaust manifold sub-assembly RH (TWC: front catalyst) and front exhaust pipe assembly with 2 new nuts and 2 new bolts.

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

7. Connect the front No. 3 exhaust pipe sub-assembly to the center exhaust pipe sub-assembly LH (TWC: rear catalyst) with the 2 compression springs and 2 bolts.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Front No. 3 Exhaust Pipe Sub-assembly
   *2	Center Exhaust Pipe Assembly
   *3	Gasket
   *a	Space between flanges: 8.5 mm (0.335 in.)

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

   NOTE:

   After the installation, check that the gaps between the flanges of the front No. 3 exhaust pipe sub-assembly and center exhaust pipe assembly are consistent front-to-rear and left-to-right.

8. Connect the exhaust pipe clamp to No. 1 exhaust pipe support bracket and tighten the bolt.

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

9. Engage the 2 clamps to connect the heated oxygen sensor (for bank 2) wire to the wire harness clamp bracket.
10. Connect the heated oxygen sensor (for bank 2) connector.
11. Pass the connector through the hole to the inside of the vehicle and install the grommet of the heated oxygen sensor (for bank 1) wire.
12. Connect the heated oxygen sensor (for bank 1) connector.

Refer to INSTALLATION [12/2015 - ]

1. Install the No. 2 engine under cover with the 2 bolts, 2 screws and clip.

1. Install the No. 1 engine under cover with the 2 bolts, 6 screws and 4 clips.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

2. Install the front wheel opening extension pad RH and front wheel opening extension pad LH with the 8 screws.

   Screw A 

   Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) 

• for 2WD:

  See step  7

• for AWD:

  See step  6

Refer to INSTALLATION [08/2016 - 11/2017] , or refer to INSTALLATION [11/2017 - ]

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 [08/2016 - 11/2017] , or refer to INITIALIZATION [11/2017 - ]

Refer to PROCEDURE - Step 94