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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) 

      Fig 1: Locating Bolts And No. 2 Exhaust Manifold Heat Insulator
      G06009243Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL EXHAUST MANIFOLD 
    1. Install a new exhaust manifold gasket.
    2. Install the exhaust manifold with the 5 nuts.

      Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf) 

      Fig 2: Locating Nuts And Exhaust Manifold
      G06009245Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL MANIFOLD STAY 
    1. Install the manifold stay with the 3 bolts.

      Torque: 43 N*m (439 kgf*cm, 32 ft.*lbf) 

      Fig 3: Locating Bolts And Manifold Stay
      G06009241Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL FRONT EXHAUST PIPE ASSEMBLY 
    1. Using a vernier caliper, measure the free length of the compression springs.
      MEASURMENT CHART

      Minimum (front) 41.5 mm (1.63 in.)
      Minimum (rear) 38.5 mm (1.52 in.)

      HINT:

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

      Fig 4: Measuring Free Length Of Compression Springs
      G05239315Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Fully insert new gaskets to the exhaust manifold and front exhaust pipe assembly.
    3. Using a plastic hammer and wooden block, tap in the 2 new gaskets until their surface are flush with the exhaust manifold and front exhaust pipe assembly.
      NOTE:
      • Be sure to install the gaskets in the correct direction.
      • 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.
      Fig 5: Identifying Gasket And Wooden Block
      G06009248Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 heated oxygen sensor connector.
      Fig 6: Locating Bolts And Compression Springs
      G06009240Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Install the No. 1 exhaust manifold heat insulator with the 4 bolts.

      Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 

  6. INSTALL AIR FUEL RATIO SENSOR  (See INSTALLATION )
  7. INSTALL NO. 2 CYLINDER HEAD COVER  (See INSTALLATION )
    Fig 7: Locating Bolts And No. 1 Exhaust Manifold Heat Insulator
    G06009239Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL OUTER COWL TOP PANEL (except TMC Made)  (See INSTALLATION )
  9. INSTALL OUTER COWL TOP PANEL (for TMC Made)  (See INSTALLATION )
  10. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY  (See INSTALLATION )
  11. INSTALL COWL TOP VENTILATOR LOUVER LH  (See INSTALLATION )
  12. INSTALL CENTER NO. 1 COWL TOP VENTILATOR LOUVER  (See INSTALLATION )
  13. INSTALL HOOD TO COWL TOP SEAL  (See INSTALLATION )
  14. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH  (See INSTALLATION )
  15. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH  (See INSTALLATION )
  16. INSTALL FRONT WIPER ARM HEAD CAP  (See INSTALLATION )
  17. INSPECT FOR EXHAUST GAS LEAK 
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