Installation [12/2019 - 10/2022]: 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 assembly LH (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 assembly RH (TWC: Front Catalyst).

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

1. Install a new exhaust manifold to head gasket (for Bank 2) to the cylinder head sub-assembly.

1. Temporarily install the exhaust manifold assembly LH (TWC: Front Catalyst) with the 4 nuts.
2. Tighten the 4 nuts in the order shown in the illustration.
   Fig 1: Exhaust Manifold Assembly LH Nuts Tightening Sequence (TWC: Front Catalyst)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

1. 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.
2. Tighten the bolt and nut in the order shown in the illustration.
   Fig 2: No. 2 Manifold Stay Bolt And Nut Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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: No. 2 Exhaust Manifold Heat Insulator Bolts Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the No. 1 sensor bracket to the cylinder head sub-assembly with the bolt.

   Torque: 30 N.m (306 kgf/cm, 22 ft.lbf) 

Refer to PROCEDURE - Step 3

Refer to PROCEDURE - Step 52 [12/2019 - 09/2020] , or refer to PROCEDURE - Step 52 [09/2020 - 10/2022]

Refer to PROCEDURE - Step 1

1. Install a new exhaust manifold to head gasket (for Bank 1) to the cylinder head sub-assembly RH.

1. Temporarily install the exhaust manifold assembly RH (TWC: Front Catalyst) with the 4 nuts.
2. 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 (TWC: Front Catalyst)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Engage the wire harness clamp.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

4. Connect the air fuel ratio sensor (for Bank 1) connector.

1. Temporarily install the manifold stay to the exhaust manifold RH (TWC: Front Catalyst) and rear engine mounting bracket with the bolt and nut.
2. Tighten the bolt and nut in the order shown in the illustration.
   Fig 5: Manifold Stay Bolt And Nut Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Refer to INSTALLATION [12/2019 - 10/2022]

1. Using a vernier caliper, measure the free length of the 2 compression springs.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Length	40 mm (1.57 in.)
   Minimum Free Length	38.5 mm (1.52 in.)

   If the free length is less than minimum, replace the compression spring.

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Front Exhaust Pipe 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 pipes when connecting them.
4. Install 2 new gaskets to the front exhaust pipe assembly.
5. Temporarily install the front exhaust pipe assembly with the 2 bolts, 4 new nuts and 2 compression springs.
6. Tighten the 4 nuts.

   Torque: 43 N.m (438 kgf/cm, 32 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 exhaust pipe assembly is consistent front-to-rear and left-to-right.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Center Exhaust Pipe Assembly (TWC: Rear Catalyst)
   *2	Front Exhaust Pipe Assembly
   *3	Gasket
   *a	Space between Flanges: 6.5 mm (0.256 in.)

8. Connect the heated oxygen sensor (for Bank 2) connector.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Tube
   *b	Wire Harness Clamp

9. Engage the 2 wire harness clamps so that the tube is positioned as shown in the illustration.
10. Connect the heated oxygen sensor (for Bank 1) connector.

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    *a	Tube
    *b	Wire Harness Clamp

11. Engage the 2 wire harness clamps so that the tube is positioned as shown in the illustration.

Refer to PROCEDURE - Step 80 [12/2019 - 09/2020] , or refer to PROCEDURE - Step 80 [09/2020 - 10/2022]

Refer to PROCEDURE - Step 81 [12/2019 - 09/2020] , or refer to PROCEDURE - Step 81 [09/2020 - 10/2022]

Refer to PROCEDURE - Step 82 [12/2019 - 09/2020] , or refer to PROCEDURE - Step 82 [09/2020 - 10/2022]

See step  6