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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 15 (Engine Intake / Exhaust System (A25A-FXS) - Service Information) >> Exhaust Manifold >> Installation [10/2022 - ] >> Procedure

Installation [10/2022 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR 
    1. for Type A:
      1. Install the No. 2 exhaust manifold heat insulator to the exhaust manifold (TWC: Front Catalyst) with the 6 bolts.

        Torque: 11 N.m (112 kgf/cm, 8 ft.lbf) 

    2. for Type B:
      1. Install the No. 2 exhaust manifold heat insulator to the exhaust manifold (TWC: Front Catalyst) with the 3 bolts.

        Torque: 11 N.m (112 kgf/cm, 8 ft.lbf) 

  2. INSTALL EXHAUST MANIFOLD (TWC: Front Catalyst) 
    1. Install a new exhaust manifold to head gasket to the cylinder head sub-assembly.
    2. Temporarily install the exhaust manifold (TWC: Front Catalyst) and No. 1 exhaust manifold heat insulator.

      HINT: 

      At this time, do not install the parts with bolts or nuts.

    3. GTY856814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Temporarily install the exhaust manifold (TWC: Front Catalyst) to the cylinder head sub-assembly with 7 new nuts.

    4. Tighten the 7 nuts in the order shown in the illustration.

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

  3. INSTALL MANIFOLD STAY 
    1. Temporarily install the manifold stay to the exhaust manifold (TWC: Front Catalyst) and cylinder block sub-assembly with the bolt and nut.
      GTY841023Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Tighten the bolt and nut in the order shown in the illustration.

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

  4. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 
    1. for Type A:
      1. Install the No. 1 exhaust manifold heat insulator to the exhaust manifold (TWC: Front Catalyst) with the 5 bolts.

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

    2. for Type B:
      1. Install the No. 1 exhaust manifold heat insulator to the exhaust manifold (TWC: Front Catalyst) with the 3 bolts.

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

  5. INSTALL WIRE HARNESS CLAMP BRACKET 
    1. Install the wire harness clamp bracket with the bolt.

      Torque: 13 N.m (133 kgf/cm, 10 ft.lbf) 

  6. INSTALL AIR FUEL RATIO SENSOR (for Sensor 1) 

    Refer to INSTALLATION [12/2019 - ]

  7. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst) 
    1. Install 2 new gaskets to the front exhaust pipe assembly (TWC: Rear Catalyst).
    2. Connect the front exhaust pipe assembly (TWC: Rear Catalyst) to the 2 exhaust pipe supports.
    3. Install the front exhaust pipe assembly (TWC: Rear Catalyst) to the exhaust manifold (TWC: Front Catalyst) and tail exhaust pipe assembly with 2 new bolts and 2 new nuts.

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

    4. Connect the air fuel ratio sensor (for sensor 2) connector.
      GTY903636Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Tube
      *b Wire Harness Clamp
    5. Engage the 2 wire harness clamps so that the tube is positioned as shown in the illustration.
    6. w/ Exhaust Heat Recirculation:
      1. Connect the outlet heater water hose D and inlet heater water hose D to the No. 2 outlet water pipe and inlet water pipe and slide the 2 clips to secure them.
        NOTE:

        When installing the outlet heater water hose D and inlet heater water hose D, ensure that the exhaust heat recirculation system is filled with coolant. Otherwise, the engine water pump assembly may be damaged.

  8. INSTALL COWL VENTILATOR PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 15

  9. INSTALL FRONT UPPER SUSPENSION TO COWL BRACE SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 16

  10. INSTALL FRONT UPPER SUSPENSION TO COWL BRACE SUB-ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  11. INSTALL FRONT FENDER SPLASH SHIELD SEAL FRONT LH 

    Refer to PROCEDURE - Step 18

  12. INSTALL FRONT FENDER SPLASH SHIELD SEAL FRONT RH 

    HINT: 

    Perform the same procedure as for the LH side.

  13. INSTALL FENDER SPLASH SHIELD SUB-ASSEMBLY REAR LH 

    Refer to PROCEDURE - Step 20

  14. INSTALL FENDER SPLASH SHIELD SUB-ASSEMBLY REAR RH 

    HINT: 

    Perform the same procedure as for the LH side.

  15. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to INSTALLATION [12/2019 - ]

  16. ADD ENGINE COOLANT (for Engine) 

    w/ Exhaust Heat Recirculation:

    Refer to PROCEDURE - Step 2

  17. INSPECT FOR COOLANT LEAK (for Engine) 

    w/ Exhaust Heat Recirculation:

    Refer to PROCEDURE - Step 1

  18. INSPECT FOR EXHAUST GAS LEAK 

    See step  6

  19. INSTALL NO. 2 ENGINE UNDER COVER ASSEMBLY 

    Refer to PROCEDURE - Step 6

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