Installation [03/2023 - ]: Procedure

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Install a new exhaust manifold to head gasket to the cylinder head sub-assembly.
   2. Using a 12 mm deep socket wrench, temporarily install the exhaust manifold to the cylinder head sub-assembly with 7 new nuts.
   3. Using the 12 mm deep socket wrench, tighten the 7 nuts in the order shown in the illustration.

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

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Torque Wrench Fulcrum Length

   -

   -

   1. Using a 10 mm union nut wrench, install the No. 2 exhaust manifold heat insulator to the exhaust manifold with the 3 bolts.

      Specified tightening torque 

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

      HINT: 

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Refer to PRECAUTION [03/2023 - ]

      • When using a 10 mm union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)): 8.8 N.m (90 kgf/cm, 78 in.lbf).

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Temporarily install the manifold stay to the exhaust manifold and cylinder block sub-assembly with the bolt and nut.
   2. Tighten the bolt and nut in the order shown in the illustration.

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

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Torque Wrench Fulcrum Length

   -

   -

   1. Using a 10 mm union nut wrench, install the No. 1 exhaust manifold heat insulator to the exhaust manifold with the 3 bolts.

      Specified tightening torque 

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

      HINT: 

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Refer to PRECAUTION [03/2023 - ]

      • When using a 10 mm union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)): 8.8 N.m (90 kgf/cm, 78 in.lbf).

Torque: 5.0 N.m (51 kgf/cm, 44 in.lbf) 

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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

      Standard Length (Front)	43 mm (1.69 in.)
      Standard Length (Rear)	40 mm (1.57 in.)
      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 gaskets to the exhaust manifold and front exhaust pipe assembly.
   3. Using a plastic hammer and wooden block, tap in each gasket until its surface is flush with the exhaust manifold and front exhaust pipe assembly.
      NOTE:

      • Be sure to install the gasket in the correct direction.
      • Do not reuse the gaskets.
      • Do not damage the gaskets.
      • Do not push in the gaskets by using the exhaust pipes when connecting them.

2. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *A	for HEV Model	*B	for PHEV Model
   *1	Exhaust Manifold	*2	Front Exhaust Pipe Assembly
   *3	Tail Exhaust Pipe Assembly	*4	Gasket
   *a	Space between Flanges: 8.5 mm (0.335in.)	*b	Space between Flanges: 6.5 mm (0.256in.)

   1. Connect the front exhaust pipe assembly to the exhaust pipe supports.
   2. Install the front exhaust pipe assembly to the exhaust manifold with the 2 compression springs and 2 bolts.

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

   3. After installation, check that the space between the flanges of the exhaust manifold and front exhaust pipe assembly is consistent front-to-rear and left-to-right.
   4. Install the front exhaust pipe assembly to the tail exhaust pipe assembly with the 2 compression springs and 2 bolts.

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

   5. After installation, check that the space between the flanges of the front exhaust pipe assembly and tail exhaust pipe assembly is consistent front-to-rear and left-to-right.
   6. Engage the wire harness clamp.
   7. Connect the air fuel ratio sensor connector.

Torque: 48.5 N.m (495 kgf/cm, 36 ft.lbf) 

Torque: 27 N.m (275 kgf/cm, 20 ft.lbf) 

Bolt 

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

Nut 

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

Bolt 

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

Nut 

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

Torque: 5.0 N.m (51 kgf/cm, 44 in.lbf) 

Bolt 

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

Nut 

Torque: 50 N.m (510 kgf/cm, 37 ft.lbf) 

Refer to INSTALLATION [12/2022 - ]

See step  7

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