Exhaust Manifold: Installation: 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.
  
  Fig 1: Locating Bolts And No. 1 Manifold Converter Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)
INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
1. Install the No. 2 exhaust manifold heat insulator with the 2 bolts.
  
  Fig 2: Locating Bolts And No. 2 Exhaust Manifold Heat Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)
INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
1. Install a new gasket.
  
  Fig 3: Identifying Exhaust Manifold Converter Tighten Nuts In Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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)
INSTALL NO. 2 MANIFOLD STAY
1. Install the No. 2 manifold stay with the bolt and nut.
  
  Fig 4: Locating Stay With Bolt And Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 44 N*m (449 kgf*cm, 33 ft.*lbf)
INSTALL MANIFOLD STAY
1. Install the manifold stay with the bolt and nut.
  
  Fig 5: Locating Manifold Stay Bolt And Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 44 N*m (449 kgf*cm, 33 ft.*lbf)
INSTALL AIR FUEL RATIO SENSOR . Refer to INSTALLATION - Step 1
INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
1. Install the No. 1 exhaust manifold heat insulator with the 4 bolts.
  
  Fig 6: Locating No. 1 Exhaust Manifold Heat Insulator Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)
INSTALL FRONT EXHAUST PIPE ASSEMBLY
1. Using a vernier caliper, measure the free length of the compression spring.
  
  Fig 7: Measuring Free Length Of Compression Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
3. Fully insert a new gasket to the exhaust manifold.
  
  Fig 8: Identifying Exhaust Manifold And Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Be sure to install the gasket in the correct direction.
  - Do not reuse the gasket.
  - Do not damage the gasket.
4. Install the front exhaust pipe assembly with the 2 bolts and 2 compression springs.
  
  Fig 9: Locating Center Exhaust Pipe Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 43 N*m (440 kgf*cm, 32 ft.*lbf)
5. Connect the heated oxygen sensor connector. (for 2WD)
INSTALL CENTER EXHAUST PIPE ASSEMBLY (for 2WD)
1. Using a vernier caliper, measure the free length of the compression spring.
  
  Fig 10: Measuring Free Length Of Compression Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Minimum 38.5 mm (1.52 in.)
  
  If the free length is less than the minimum, replace the compression spring.
2. Fully insert a new gasket to the center exhaust pipe assembly.
  
  Fig 11: Identifying Center Exhaust Pipe Assembly And Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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)
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 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.
  
  Fig 13: Measuring Free Length Of Compression Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Minimum 38.5 mm (1.52 in.)
  
  If the free length is less than the minimum, replace the compression spring.
2. Fully insert a new gasket to the center exhaust pipe assembly.
  
  Fig 14: Identifying Center Exhaust Pipe Assembly And Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
5. Install the center exhaust pipe assembly with the 4 bolts and 2 compression springs.
  
  Fig 15: Locating Bolts And Compression Springs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 43 N*m (440 kgf*cm, 32 ft.*lbf)
6. Connect the heated oxygen sensor connector.
INSTALL GENERATOR ASSEMBLY . Refer to INSTALLATION - Step 1
INSTALL V-RIBBED BELT . Refer to INSTALLATION - Step 1
INSTALL ENGINE UNDER COVER RH
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
INSPECT FOR EXHAUST GAS LEAK