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Exhaust Manifold: Installation

WARNING: This page is about a different variant/trim than selected.
  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 No. 2 Exhaust Manifold Heat Insulator Bolts
      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 Exhaust Manifold Nuts
      G06009242Courtesy 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 Manifold Stay Bolts
      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.
      COMPRESSION SPRINGS FREE LENGTH REFERENCE

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

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

    2. Fully insert new gaskets to the exhaust manifold and front exhaust pipe assembly.
      Fig 4: Measuring Free Length Of Compression Springs
      G05239315Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a plastic hammer and a wooden block, tap in the 2 new gaskets until their surfaces 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: Tapping In Gaskets Until Their Surfaces Are Flush With Exhaust Manifold And Front Exhaust Pipe Assembly
      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 Front Exhaust Pipe Assembly 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 OUTER COWL TOP PANEL  (See INSTALLATION )
    Fig 7: Locating No. 1 Exhaust Manifold Heat Insulator Bolts
    G06009239Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY  (See INSTALLATION )
  9. INSTALL COWL TOP VENTILATOR LOUVER LH  (See INSTALLATION )
  10. INSTALL COWL TOP VENTILATOR LOUVER RH  (See INSTALLATION )
  11. INSTALL HOOD TO COWL TOP SEAL  (See INSTALLATION )
  12. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH  (See INSTALLATION )
  13. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH  (See INSTALLATION )
  14. INSTALL FRONT WIPER ARM HEAD CAP  (See INSTALLATION )
  15. INSPECT FOR EXHAUST GAS LEAK 
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