Toyota Avalon (XX50) 2019-2022 Service & Repair Manual: Installation

INSTALLATION

PROCEDURE

1. INSTALL STUD BOLT

HINT:

If a stud bolt is deformed or its threads are damaged, replace it.

(a) 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}

2. INSTALL EXHAUST MANIFOLD TO HEAD GASKET (for Bank 2)

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

3. INSTALL EXHAUST MANIFOLD ASSEMBLY LH (TWC: Front Catalyst)

(a) Temporarily install the exhaust manifold assembly LH (TWC: Front Catalyst) with the 4 nuts.

(b) 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.

(c) Using a 12 mm deep socket wrench, tighten the 4 nuts in the order shown in the illustration. Torque: 21 N·m {214 kgf·cm, 15 ft·lbf}

(d) Tighten the bolt and nut in the order shown in the illustration.

	Bolt
	Nut

Torque:

Nut :

35 N·m {357 kgf·cm, 26 ft·lbf}

Bolt :

34 N·m {347 kgf·cm, 25 ft·lbf}

4. CONNECT NO. 5 WATER BY-PASS HOSE

(a) Engage the 2 clamps to connect the No. 5 water by-pass hose and No. 6 water by-pass hose to the hose clamp.

5. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

(a) 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}

6. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

Click here

7. INSTALL AIR FUEL RATIO SENSOR (for Bank 2)

Click here

8. INSTALL COOL AIR INTAKE DUCT SEAL

Click here

9. INSTALL V-BANK COVER SUB-ASSEMBLY

Click here

10. INSTALL EXHAUST MANIFOLD TO HEAD GASKET (for Bank 1)

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

11. INSTALL EXHAUST MANIFOLD ASSEMBLY RH (TWC: Front Catalyst)

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

(b) Using a 12 mm deep socket wrench, tighten the 4 nuts in the order shown in the illustration. Torque: 21 N·m {214 kgf·cm, 15 ft·lbf}

12. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

(a) Install the No. 1 exhaust manifold heat insulator to the exhaust manifold assembly RH (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}

*a Temporarily Tighten

13. INSTALL AIR FUEL RATIO SENSOR (for Bank 1)

Click here

14. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)

(a) Install 3 new gaskets to the front exhaust pipe assembly (TWC: Rear Catalyst).

(b) Connect the front exhaust pipe assembly (TWC: Rear Catalyst) to the exhaust pipe support.

(c) Install the front exhaust pipe assembly (TWC: Rear Catalyst) with 4 new bolts and 4 new nuts.

Torque:

43 N·m {438 kgf·cm, 32 ft·lbf}

(d) Engage the 2 wire harness clamps.

(e) Connect the 2 heated oxygen sensor connectors.

15. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET (for Lower Side)

Click here

16. INSTALL BODY MOUNTING PLATE

Click here

17. INSTALL FRONT FLOOR COVER LH

Click here

18. INSTALL FRONT FLOOR COVER RH

Click here

19. INSPECT FOR EXHAUST GAS LEAK

Click here

20. INSTALL REAR ENGINE UNDER COVER RH

Click here

21. INSTALL NO. 1 ENGINE UNDER COVER

Click here

22. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH

Click here

23. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH

Click here