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. A003VIVE01
      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 NO.2


    1. A003X3XE07
      Text in Illustration
      *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.) and a torque wrench with a fulcrum length of 300 mm (11.8 in.) Click here.

      • The "with SST" 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 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. A003Z73

      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. A003WOME17
      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 gaskets by using the exhaust pipe when connecting it.

    4. Connect the front exhaust pipe assembly to the 2 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. Connect the 3 clamps and oxygen sensor connector.

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


    1. A003Z73

      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. A003WOME17
      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 gaskets by using the exhaust pipe when connecting it.

    4. Connect the front exhaust pipe assembly to the 2 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 3 clamps and oxygen sensor connector.

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


    1. Tighten the radiator drain cock plug.

    2. A003ZK5E01
      Text in Illustration
      *1 B Line

      Add coolant to B line of the reserve tank.

      Standard Capacity
      Item Capacity
      Engine coolant

      w/ Exhaust Heat Recirculation System:

      6.9 liters (7.3 US qts, 6.1 lmp. qts)

      w/o Exhaust Heat Recirculation System:

      6.5 liters (6.9 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.

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

      If the coolant level is low, add coolant.

    4. Put the engine in inspection mode Click here.

    5. Install the reserve tank cap.

    6. 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. (●1)

        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 fans.

      2. Stop the engine and wait until the coolant cools down. Then if the coolant level is below the low line, add coolant so that the level will be between the full and low lines. (●2)

      3. Repeat the steps from (●1) to (●2) until the coolant level of the reserve tank remains above the low line.

    7. A003ZK5E02
      Text in Illustration
      *1 Full Line
      *2 Low Line

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

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

  10. INSPECT FOR COOLANT LEAK (for Engine w/ Exhaust Heat Recirculation System)

    CAUTION:

    Do not remove the reserve 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 reserve tank cap.

    2. A003VSX

      Fill the reserve tank 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, the heater hose around the engine coolant temperature sensor 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 reserve 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 FRONT NO. 3 ENGINE UNDER COVER


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

  13. INSTALL NO. 1 ENGINE UNDER COVER

  14. INSTALL NO. 2 CYLINDER HEAD COVER


    1. A003WMM

      Engage the 3 clips to install the cover.

      Note


      • Be sure to engage the clips securely.

      • Do not apply excessive force or hit the cover to engage the clips. This may cause the cover to break.

  15. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for LHD)


    1. Install the outer cowl top panel sub-assembly with the 9 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    2. w/ Wiper Deicer:

      Engage the 3 clamps to install the wire harness.

    3. Engage the clamp to install the wire harness.

  16. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for RHD)


    1. Install the outer cowl top panel sub-assembly with the 9 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    2. w/ Wiper Deicer:

      Engage the 3 clamps to install the wire harness.

    3. Engage the clamp to install the wire harness.

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


    1. Install the cowl body mounting reinforcement LH with the 2 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

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


    1. Install the cowl body mounting reinforcement RH with the 2 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  19. INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for LHD)


    1. Engage the claw and guide to install the No. 2 heater air duct splash shield seal.

  20. INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)


    1. Engage the claw and guide to install the No. 2 heater air duct splash shield seal.

  21. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL (for LHD)


    1. Engage the 2 claws to install the No. 1 heater air duct splash shield seal.

  22. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)


    1. Engage the 2 claws to install the No. 1 heater air duct splash shield seal.

  23. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  24. INSPECT FOR EXHAUST GAS LEAK