Exhaust Manifold: Installation

WARNING: This page is about a different variant/trim than selected.

INSTALL AIR FUEL RATIO SENSOR (See INSTALLATION )

Fig 1: Locating Bolt And No. 2 Exhaust Manifold Heat Insulator
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
1. Install the No. 2 exhaust manifold heat insulator with the bolt.
  Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf)
Fig 2: Locating Bolt And No. 2 Exhaust Manifold Heat Insulator
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL EXHAUST MANIFOLD ASSEMBLY
1. Install a new gasket onto the cylinder head.
  
  Fig 3: Locating Exhaust Manifold Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Temporarily install the exhaust manifold assembly with the 5 nuts.
3. Tighten the 5 nuts in the sequence shown in the illustration.
  Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf)
  
  Fig 4: Locating Exhaust Manifold Assembly And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the plate with the bolt.
  Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf)
Fig 5: Locating Plate With Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 MANIFOLD STAY
1. Install the No. 2 manifold stay with the bolt and nut.
  Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
  
  Fig 6: Locating No. 2 Manifold Stay With Bolt And Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the wire harness bracket with the bolt.
  Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)
Fig 7: Locating Wire Harness Bracket And Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANIFOLD STAY
1. Install the manifold stay with the bolt and nut.
  Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
Fig 8: Locating Manifold Stay With Bolt And Nut
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT EXHAUST PIPE ASSEMBLY
1. Using a vernier caliper, measure the free length of the compression spring.
  Minimum length: 41.5 mm (1.64 in.)
  
  If the length is less than the minimum, replace the compression spring.
2. Fully insert a new gasket to the exhaust manifold assembly.
  
  Fig 9: Measuring Free Length Of Compression Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a plastic hammer and wooden block, tap in the new gasket until its surface is flush with the exhaust manifold assembly.
  NOTE:
  - Be sure to install the gasket in the correct direction.
  - Do not reuse the gasket.
  - Do not damage the gasket.
  - Do not push in the gasket by using the exhaust pipe when connecting it.
4. Install a new gasket to the front exhaust pipe.
  
  Fig 10: Identifying Wooden Block And Exhaust Manifold Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the front exhaust pipe with the 2 compression springs and 4 bolts.
  Torque: 48 N*m (489 kgf*cm, 35 ft.*lbf) for bolt A
  
  56 N*m (571 kgf*cm, 41 ft.*lbf) for bolt B
  
  Fig 11: Locating Front Exhaust Pipe, Compression Springs And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Connect the clamp and connector.
INSPECT FOR EXHAUST GAS LEAK

Fig 12: Locating Clamp And Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT FLOOR COVER LH
1. Connect the 3 clips.
2. Install the front floor cover LH with the 2 screws and 4 bolts.
INSTALL UNDER NO. 1 ENGINE COVER

Fig 13: Locating Front Floor Cover LH With Screws And Bolts