EXHAUST MANIFOLD INSTALLATION


  1. 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 }

  2. INSTALL EXHAUST MANIFOLD


    1. A003SA1E01
      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 }

  3. INSTALL MANIFOLD STAY


    1. Install the manifold stay with the 3 bolts.

      Torque:
      43 N*m  { 439 kgf*cm, 32 ft.*lbf }

  4. INSTALL AIR FUEL RATIO SENSOR


    1. A003TPSE02
      *a Fulcrum length 30 mm
      *b Fulcrum length 300 mm

      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.).

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

    2. Connect the air fuel ratio sensor connector and clamp.

  5. 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 }

  6. INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR


    1. Install the front No. 1 floor heat insulator with the 3 nuts.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  7. 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 assembly may be damaged.


    1. A003RI4

      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.

    2. Fully insert 2 new gaskets to the exhaust manifold and front exhaust pipe assembly.

    3. A003SHVE17
      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 each new gasket 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 gasket by using the exhaust pipe when connecting it.

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

    5. Install the front exhaust pipe assembly with the 4 bolts and 4 compression springs.

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

    6. Connect the 2 heater water hoses.

    7. A003UDL

      Connect the 3 clamps and oxygen sensor connector.

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


    1. A003RI4

      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.

    2. Fully insert 2 new gaskets to the exhaust manifold and front exhaust pipe assembly.

    3. A003SHVE17
      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 each new gasket 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 gasket by using the exhaust pipe when connecting it.

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

    5. Install the front exhaust pipe assembly with the 4 bolts and 4 compression springs.

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

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


    1. Tighten the radiator drain cock plug.

    2. Connect the hose to the air release valve. (w/ Air Release Valve)

    3. Loosen the air release valve. (w/ Air Release Valve)

    4. 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. (w/ Air Release Valve)

    5. Disconnect the hose from the air release valve. (w/ Air Release Valve)

    6. A003TGQE01
      Text in Illustration
      *1 B Line

      Add TOYOTA Super Long Life Coolant (SLLC) to the B line on 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.

    7. 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.

    8. Put the engine in inspection mode Click here.

    9. Install the reservoir tank cap.

    10. 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 the 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.

    11. A003TGQE02
      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 lines.

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

  10. 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. A003T8A

      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 a radiator 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.

  11. 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 }

  12. INSTALL NO. 2 ENGINE UNDER COVER


    1. Install the No. 2 engine under cover with the 4 clips.

  13. INSTALL CENTER NO. 4 ENGINE UNDER COVER

  14. INSTALL NO. 1 ENGINE UNDER COVER

  15. INSTALL OUTER COWL TOP PANEL (for LHD)


    1. A003SJJ

      Install the outer cowl top panel with the 8 bolts and nut.

      Torque:
      Bolt
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }
      Nut
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    2. Engage the clamp.

    3. A003UBYE01
      Text in Illustration
      *1 No. 1 Heater Air Duct Splash Shield Seal
      *2 Water Guard Plate RH

      Bend the No. 1 heater air duct splash shield seal and water guard plate RH, and engage each claw.

  16. INSTALL OUTER COWL TOP PANEL (for RHD)


    1. A003UWL

      Install the outer cowl top panel with the 8 bolts and nut.

      Torque:
      Bolt
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }
      Nut
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    2. Engage the clamp of the wire harness.

    3. A003SKXE01
      Text in Illustration
      *1 Water Guard Plate RH
      *2 No. 1 Heater Air Duct Splash Shield Seal

      Bend the water guard plate RH and No. 1 heater air duct splash shield seal, and engage each claw.

  17. INSTALL COWL BODY MOUNTING REINFORCEMENT LH (for LHD)


    1. A003TIT

      Install the cowl body mounting reinforcement LH with the 3 bolts.

      Torque:
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }

  18. INSTALL COWL BODY MOUNTING REINFORCEMENT LH (for RHD)


    1. A003TW0

      Install the cowl body mounting reinforcement LH with the 3 bolts.

      Torque:
      8.8 N*m  { 90 kgf*cm, 73 in.*lbf }

  19. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  20. INSPECT FOR EXHAUST GAS LEAK