Exhaust Manifold: Installation

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

INSTALL NO. 1 MANIFOLD CONVERTER INSULATOR
1. Install the No. 1 manifold converter insulator with the 4 bolts.
  Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)
  
  Fig 1: Locating No. 1 Manifold Converter Insulator Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
1. Install the No. 2 exhaust manifold heat insulator with the 2 bolts.
  Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)
  
  Fig 2: Locating No. 2 Exhaust Manifold Heat Insulator Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
1. Install a new gasket.
2. Install the exhaust manifold converter sub-assembly with the 5 nuts in the order shown in the illustration.
  Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)
  
  Fig 3: Identifying Exhaust Manifold Converter Sub-Assembly Nuts Installing Order
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 MANIFOLD STAY
1. Install the No. 2 manifold stay with the bolt and nut.
  Torque: 44 N*m (449 kgf*cm, 33 ft.*lbf)
  
  Fig 4: Locating No. 2 Manifold Stay Bolt And Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANIFOLD STAY
1. Install the manifold stay with the bolt and nut.
  Torque: 44 N*m (449 kgf*cm, 33 ft.*lbf)
INSTALL AIR FUEL RATIO SENSOR (See INSTALLATION )

Fig 5: Locating Manifold Stay Bolt And Nut
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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)
  
  Fig 6: Locating No. 1 Exhaust Manifold Heat Insulator Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT EXHAUST PIPE ASSEMBLY
1. Using a vernier caliper, measure the free length of the compression spring.
  COMPRESSION SPRING FREE LENGTH REFERENCE
  
  Minimum 41.5 mm (1.63 in.)
  
  If the free length is less than the minimum, replace the compression spring.
2. Remove the remains on exhaust manifold converter with wire brush.
  
  Fig 7: Measuring Free Length Of Compression Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Fully insert a new gasket to the exhaust manifold.
  NOTE:
  - Be sure to install the gasket in the correct direction.
  - Do not reuse the gasket.
  - Do not damage the gasket.
    
    Fig 8: Identifying Exhaust Manifold Gasket
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the front exhaust pipe assembly with the 2 bolts and 2 compression springs.
  Torque: 43 N*m (440 kgf*cm, 32 ft.*lbf)
5. Connect the heated oxygen sensor connector, (for 2WD)
  
  Fig 9: Locating Front Exhaust Pipe Assembly Bolts And Compression Springs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CENTER EXHAUST PIPE ASSEMBLY (for 2WD)
1. Using a vernier caliper, measure the free length of the compression spring.
  COMPRESSION SPRING FREE LENGTH REFERENCE
  
  Minimum 38.5 mm (1.52 in.)
  
  If the free length is less than the minimum, replace the compression spring.
  
  Fig 10: Measuring Free Length Of Compression Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Fully insert a new gasket to the center exhaust pipe assembly.
  NOTE:
  - Be sure to install the gasket in the correct direction.
  - Do not reuse the gasket.
  - Do not damage the gasket.
3. Install a new gasket to the front exhaust pipe assembly.
4. Connect the center exhaust pipe assembly to the 2 exhaust pipe supports, (for Torsion beam type suspension)
  
  Fig 11: Identifying Center Exhaust Pipe Assembly Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Connect the center exhaust pipe assembly to the 3 exhaust pipe supports, (for Double wishbone type suspension)
6. Install the center exhaust pipe assembly with the 4 bolts and 2 compression springs.
  
  Fig 12: Locating Center Exhaust Pipe Assembly Bolts And Compression Springs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 43 N*m (440 kgf*cm, 32 ft.*lbf)
INSTALL CENTER EXHAUST PIPE ASSEMBLY (for 4WD)
1. Using a vernier caliper, measure the free length of the compression spring.
  COMPRESSION SPRING FREE LENGTH REFERENCE
  
  Minimum 38.5 mm (1.52 in.)
  
  If the free length is less than the minimum, replace the compression spring.
  
  Fig 13: Measuring Free Length Of Compression Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Fully insert a new gasket to the center exhaust pipe assembly.
  NOTE:
  - Be sure to install the gasket in the correct direction.
  - Do not reuse the gasket.
  - Do not damage the gasket.
3. Install a new gasket to the front exhaust pipe assembly.
4. Connect the center exhaust pipe assembly to the 3 exhaust pipe supports.
  
  Fig 14: Identifying Center Exhaust Pipe Assembly Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the center exhaust pipe assembly with the 4 bolts and 2 compression springs.
  Torque: 43 N*m (440 kgf*cm, 32 ft.*lbf)
6. Connect the heated oxygen sensor connector.
INSTALL GENERATOR ASSEMBLY (See INSTALLATION )
INSTALL V-RIBBED BELT (See REMOVAL )
INSTALL ENGINE UNDER COVER RH

Fig 15: Locating Center Exhaust Pipe Assembly Bolts And Compression Springs
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See INITIALIZATION ).
INSPECT FOR EXHAUST GAS LEAK