EXHAUST PIPE INSTALLATION


  1. INSTALL FRONT EXHAUST PIPE ASSEMBLY (w/ Exhaust Heat Recirculation System)

    Note

    When installing the water hose, ensure that the exhaust heat recirculation system is filled with coolant. Otherwise, the engine water pump may be damaged.


    1. A01JCCE

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

      Minimum 41.5 mm (1.64 in.)

      Tech Tips

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

    2. Fully insert a new gasket to the exhaust manifold.

    3. A01JANBE17
      Text in Illustration
      *1 Exhaust Manifold
      *2 Gasket
      *3 Wooden Block

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

      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 pipe when connecting it.

    4. Connect the front exhaust pipe assembly to the 3 exhaust pipe supports.

    5. A01JCYB

      Install the front exhaust pipe assembly with the 2 bolts and 2 compression springs.

      Torque:
      43 N*m  { 440 kgf*cm, 32 ft.*lbf }
    6. A01JC0H

      Connect the 2 heater water hoses.

  2. INSTALL FRONT EXHAUST PIPE ASSEMBLY (w/o Exhaust Heat Recirculation System)


    1. A01JCCE

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

      Minimum 41.5 mm (1.64 in.)

      Tech Tips

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

    2. Fully insert a new gasket to the exhaust manifold.

    3. A01JANBE17
      Text in Illustration
      *1 Exhaust Manifold
      *2 Gasket
      *3 Wooden Block

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

      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 pipe when connecting it.

    4. Connect the front exhaust pipe assembly to the 3 exhaust pipe supports.

    5. A01JCYB

      Install the front exhaust pipe assembly with the 2 bolts and 2 compression springs.

      Torque:
      43 N*m  { 440 kgf*cm, 32 ft.*lbf }

  3. INSTALL OXYGEN SENSOR


    1. A01JCO0E01
      Text in Illustration
      *1

      Fulcrum Length

      300 mm
      *2

      Fulcrum Length

      30 mm

      Using SST, install the heated oxygen sensor onto the front exhaust pipe.

      SST
      09224-00010
      Torque:
      without SST
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }
      with SST
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

      Note


      • This torque value can be obtained by using a torque wrench with a fulcrum length of 300 mm (11.81 in.) and SST with a length of 30 mm (1.18 in.) Click here.

      • This torque value is effective when SST is parallel to the torque wrench.

    2. A01J8EE

      Connect the wire harness to install the wire harness clamp bracket.

    3. A01JA6S

      Install the wire harness clamp bracket with the bolt.

      Torque:
      12 N*m  { 127 kgf*cm, 9 ft.*lbf }

    4. Install the wire harness bracket.

    5. Connect the heated oxygen sensor connector.

  4. INSTALL FRONT CENTER FLOOR BRACE


    1. A01JBGZ

      Install the front center floor brace with the 4 bolts.

      Torque:
      51 N*m  { 520 kgf*cm, 38 ft.*lbf }

  5. INSTALL FRONT NO. 3 ENGINE UNDER COVER


    1. A01JASK

      Install the front No. 3 engine under cover with the 4 clips.

  6. INSTALL TAIL EXHAUST PIPE ASSEMBLY


    1. A01JCCE

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

      Minimum 38.5 mm (1.52 in.)

      Tech Tips

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

    2. Fully insert a new gasket to the front exhaust pipe assembly.

    3. A01JANBE17
      Text in Illustration
      *1 Front Exhaust Pipe Assembly
      *2 Gasket
      *3 Wooden Block

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

      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 pipe when connecting it.

    4. Connect the tail exhaust pipe assembly to the 2 exhaust pipe supports.

    5. A01JB7Q

      Install the tail exhaust pipe assembly with the 2 bolts and 2 compression springs.

      Torque:
      43 N*m  { 440 kgf*cm, 32 ft.*lbf }

  7. ADD COOLANT (for Engine with Exhaust Heat Recirculation System)


    1. Tighten the radiator drain cock plug.

    2. Tighten the cylinder block drain cock plug.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

    3. Remove the reservoir tank cap.

    4. Connect the hose to the air release valve.

    5. Loosen the air release valve.

    6. Add TOYOTA Super Long Life Coolant (SLLC) to the reservoir tank filler opening until coolant overflows from the air release valve. Then tighten the air release valve.

      Standard Capacity
      Item Capacity
      Engine coolant

      w/ Exhaust Heat Recirculation System:

      7.2 liters (7.6 US qts, 6.3 lmp. qts)

      w/o Exhaust Heat Recirculation System:

      6.5 liters (6.8 US qts, 5.7 lmp. qts)

      Tech Tips


      • TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology is a combination of low phosphates and organic acids).

      • Contact your TOYOTA dealer for further details.

      Note

      Never use water as a substitute for engine coolant.

    7. Disconnect the hose from the air release valve.

    8. A01JC0TE01
      Text in Illustration
      *1 B Line

      Add coolant to B line of the reservoir tank.

    9. Squeeze the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.

      If the coolant level is low, add coolant.

    10. Put the engine in inspection mode Click here.

    11. Install the reservoir tank cap and air release valve, and warm up the engine sufficiently.

    12. Bleed air from the cooling system.

      Note


      • Before starting the engine, turn the A/C switch off.

      • Adjust the heater control to the maximum hot setting.

      • Adjust the blower speed to low setting.


      1. Warm up the engine until the thermostat opens. While the thermostat is open, allow the coolant to circulate for several minutes.

        Tech Tips

        The thermostat opening timing can be confirmed by squeezing the inlet radiator hose by hand, and sensing vibrations when the engine coolant starts to flow inside the hose.

        CAUTION:

        When squeezing the radiator hose:

        • Wear protective gloves.

        • Be careful as the radiator hoses are hot.

        • Keep your hands away from the radiator fan.

      2. Squeeze the inlet and outlet radiator hoses several times by hand to bleed air from the system.

        CAUTION:

        When squeezing the radiator hose:

        • Wear protective gloves.

        • Be careful as the radiator hoses are hot.

        • Keep your hands away from the radiator fan.

    13. A01JC0TE02
      Text in Illustration
      *1 Full Line
      *2 Low Line

      After the engine has cooled down, check that the coolant level is between full and low.

      If the coolant level is low, add coolant to the full line on the reservoir tank.

  8. INSPECT FOR COOLANT LEAK (for Engine with Exhaust Heat Recirculation System)

    CAUTION:

    Do not remove the reservoir tank cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    Note

    Before performing each inspection, turn the A/C switch off.


    1. Remove the reservoir tank cap.

    2. A01JB8R

      Fill the radiator and reservoir with coolant, and then attach a radiator cap tester.

    3. Put the engine in inspection mode Click here.

    4. Warm up the engine.

    5. Using the reservoir cap tester, increase the pressure inside the radiator to 108 kPa (1.1 kgf/cm2, 16 psi), and check that the pressure does not drop. If the pressure drops, check the hoses, radiator, front exhaust pipe assembly and the heater hose around and engine water pump assembly for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.

    6. Remove the radiator cap tester.

    7. Install the reservoir tank cap.

  9. INSPECT FOR EXHAUST GAS LEAK