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Exhaust Manifold: Replacement

WARNING: This page is about a different car, the 2004 Lexus SC 430. However, it is still accessible from the selected car via links, so may be relevant.
  1. REMOVE ENGINE ASSY (See  REMOVAL AND INSTALLATION  ) 
  2. REMOVE HEATED OXYGEN SENSOR 
  3. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1 
  4. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.2 
  5. REMOVE EXHAUST MANIFOLD SUB-ASSY RH 
  6. REMOVE EXHAUST MANIFOLD SUB-ASSY LH 
  7. INSPECT EXHAUST MANIFOLD SUB-ASSY RH 
    1. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage.

      Maximum warpage: 0.50 mm (0.0197 in.) 

      If the warpage is greater than maximum, replace the manifold.

      Fig 1: Measuring Surface Contacting Cylinder Head For Warpage
      G00926776Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSPECT EXHAUST MANIFOLD SUB-ASSY LH 
    1. Employ the same manner described above to the other side.
  9. INSTALL EXHAUST MANIFOLD SUB-ASSY LH 
    NOTE:
    • Install a new gasket with the white mark facing the exhaust manifold side. 
    • Uniformly tighten the nuts diagonally. 

      Torque: 44 N.m (450 kgf.cm, 32 ft.lbf) 

  10. INSTALL EXHAUST MANIFOLD SUB-ASSY RH 
    1. Employ the same manner described above to the other side.
  11. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2 
  12. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1 
  13. INSTALL HEATED OXYGEN SENSOR 
  14. INSTALL ENGINE ASSY (See  REMOVAL AND INSTALLATION  ) 
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