EXHAUST MANIFOLD INSTALLATION

INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
1. Install the No. 2 exhaust manifold heat insulator with the 3 bolts.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
INSTALL EXHAUST MANIFOLD
1. Text in Illustration
  
  *A Nut Type A
  
  *B Nut Type B
  
  Install 2 new gaskets and the exhaust manifold with the 7 nuts.
  
  Torque:
  
  Type A
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
  
  Type B
  
  37 N*m { 377 kgf*cm, 27 ft.*lbf }
INSTALL MANIFOLD STAY
1. Install the manifold stay with the 3 bolts.
  
  Torque:
  
  43 N*m { 439 kgf*cm, 32 ft.*lbf }
INSTALL AIR FUEL RATIO SENSOR
1. Using SST, install the air fuel ratio sensor.
  
  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
  
  The "with SST" torque value is effective when using SST with a fulcrum length of 30 mm (1.18 in.).
  
  The "with SST" torque value is effective when using a torque wrench with a fulcrum length of 300 mm (11.81 in.) Click here.
  
  This torque value is effective when SST is parallel to the torque wrench.
2. Connect the air fuel ratio sensor connector and clamp.
INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
1. Install the No. 1 exhaust manifold heat insulator with the 3 bolts.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR
1. Install the No. 1 floor heat insulator with the 3 nuts.
  
  Torque:
  
  5.5 N*m { 56 kgf*cm, 49 in.*lbf }

Text in Illustration
*A	Nut Type A
*B	Nut Type B

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.

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

Minimum (front) 41.5 mm (1.64 in.)

Minimum (rear) 38.5 mm (1.52 in.)

Tech Tips

If the free length is less than minimum, replace the compression spring.
Fully insert 2 new gaskets to the exhaust manifold and front exhaust pipe assembly.

Text in Illustration
*1	Exhaust Manifold and Front Exhaust Pipe Assembly
*2	Gasket
*3	Wooden Block

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

Note

Be careful with the installation direction of the gaskets.
Do not reuse the gaskets.
Do not damage the gaskets.
Do not push in the gaskets by using the exhaust pipe when connecting it.

Connect the front exhaust pipe assembly to the 3 exhaust pipe supports.
Install the front exhaust pipe assembly with the 4 bolts and 4 compression springs.

Torque:

43 N*m { 440 kgf*cm, 32 ft.*lbf }
Connect the 2 heater water hoses.
Connect the 3 clamps and oxygen sensor connector.

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

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

Minimum (front) 41.5 mm (1.64 in.)

Minimum (rear) 38.5 mm (1.52 in.)

Tech Tips

If the free length is less than minimum, replace the compression spring.
Fully insert 2 new gaskets to the exhaust manifold and front exhaust pipe assembly.

Text in Illustration
*1	Exhaust Manifold and Front Exhaust Pipe Assembly
*2	Gasket
*3	Wooden Block

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

Note

Be careful with the installation direction of the gaskets.
Do not reuse the gaskets.
Do not damage the gaskets.
Do not push in the gaskets by using the exhaust pipe when connecting it.

Connect the front exhaust pipe assembly to the 3 exhaust pipe supports.
Install the front exhaust pipe assembly with the 4 bolts and 4 compression springs.

Torque:

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

ADD COOLANT (for Engine with Exhaust Heat Recirculation System)

Tighten the radiator drain cock plug.
Remove the reservoir tank cap.

Text in Illustration
*1	B Line

Add coolant to B line of the reservoir tank.

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).

Note

Never use water as a substitute for engine coolant.

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.
Install the reservoir tank cap.
Put the engine in inspection mode Click here.
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.
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.

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. 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.
INSTALL FRONT CENTER FLOOR BRACE
1. Install the front center floor brace with the 4 bolts.
  
  Torque:
  
  51 N*m { 520 kgf*cm, 38 ft.*lbf }
INSTALL FRONT NO. 3 ENGINE UNDER COVER
1. Install the front No. 3 engine under cover with the 4 clips.
INSTALL NO. 2 ENGINE UNDER COVER
INSTALL NO. 1 ENGINE UNDER COVER
INSPECT FOR EXHAUST GAS LEAK

Minimum (front)	41.5 mm (1.64 in.)
Minimum (rear)	38.5 mm (1.52 in.)

Text in Illustration
*1	Full Line
*2	Low Line