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Installation [04/2018 - ]: Procedure

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  1. INSTALL STUD BOLT 

    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 assembly LH (TWC: Front Catalyst).
      GTY766170Courtesy 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.
  3. INSTALL EXHAUST MANIFOLD ASSEMBLY LH (TWC: Front Catalyst) 
    1. Temporarily install the exhaust manifold assembly LH (TWC: Front Catalyst) 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 Nuts Tightening Sequence
      GTY749375Courtesy 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: Exhaust Manifold Brace Tightening Sequence (2GR-FKS) LH
      GTY744296Courtesy 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. CONNECT NO. 5 WATER BY-PASS HOSE 
    1. Engage the 2 clamps to connect the No. 5 water by-pass hose and No. 6 water by-pass hose to the hose clamp.
  5. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Install the No. 2 exhaust manifold heat insulator to the exhaust manifold assembly LH (TWC: Front Catalyst) with the 3 bolts in the order shown in the illustration.

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

      Fig 3: Exhaust Manifold Heat Insulator Bolts Tightening Sequence (2GR-FKS) LH
      GTY746308Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE 

    Refer to PROCEDURE - Step 5

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

    Refer to PROCEDURE - Step 2

  8. INSTALL COOL AIR INTAKE DUCT SEAL 

    Refer to PROCEDURE - Step 2 [04/2018 - 08/2021] , or refer to PROCEDURE - Step 2 [08/2021 - ]

  9. INSTALL V-BANK COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 46

  10. 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.
  11. INSTALL EXHAUST MANIFOLD ASSEMBLY RH (TWC: Front Catalyst) 
    1. Temporarily install the exhaust manifold assembly RH (TWC: Front Catalyst) with the 4 nuts.
    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) 

      Fig 4: Exhaust Manifold Assembly RH Nuts Tightening Sequence
      GTY762770Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Install the No. 1 exhaust manifold heat insulator to the exhaust manifold assembly RH (TWC: Front Catalyst) with the 3 bolts in the order shown in the illustration.

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

      Fig 5: Exhaust Manifold Heat Insulator Bolts Tightening Sequence (2GR-FKS) RH
      GTY764515Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Temporarily Tighten
  13. INSTALL AIR FUEL RATIO SENSOR (for Bank 1) 

    Refer to PROCEDURE - Step 1

  14. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst) 
    1. Install 3 new gaskets to the front exhaust pipe assembly (TWC: Rear Catalyst).
    2. Connect the front exhaust pipe assembly (TWC: Rear Catalyst) to the exhaust pipe support.
    3. Install the front exhaust pipe assembly (TWC: Rear Catalyst) with 4 new bolts and 4 new nuts.

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

    4. Engage the 2 wire harness clamps.
    5. Connect the 2 heated oxygen sensor connectors.
  15. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET (for Lower Side) 

    See step  5

  16. INSTALL BODY MOUNTING PLATE 

    See step  6

  17. INSTALL FRONT FLOOR COVER LH 

    See step  10

  18. INSTALL FRONT FLOOR COVER RH 

    See step  11

  19. INSPECT FOR EXHAUST GAS LEAK 

    See step  14

  20. INSTALL REAR ENGINE UNDER COVER RH 

    Refer to PROCEDURE - Step 67

  21. INSTALL NO. 1 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 69

  22. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH 

    Refer to PROCEDURE - Step 70

  23. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH 

    Refer to PROCEDURE - Step 71

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