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Exhaust Manifold: Installation

  1. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH 
    1. Install a new gasket to the cylinder head and a new gasket to the No. 2 air tube.

      HINT:

      • Install the exhaust manifold gasket with the gasket tab facing toward the front of the engine.
      • Install the air tube gasket with the gasket claws facing the tube side.
        Fig 1: Identifying Air Tube And Gasket Claws
        G05638061Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Temporarily install the exhaust manifold with the 2 nuts labeled A and 8 new nuts.
    3. Uniformly tighten the nuts that are not labeled A, and then tighten the 2 nuts labeled A.

      Torque: 

      for nut A 

      10 N*m (102 kgf*cm, 7 ft.*lbf) 

      except nut A 

      21 N*m (214 kgf*cm, 15 ft.*lbf) 

      Fig 2: Locating Exhaust Manifold Nuts
      G05638062Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the insulator to the exhaust manifold with the 2 nuts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      Fig 3: Locating Insulator Nuts
      G05638059Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Install the heat insulator with the 3 bolts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      Fig 4: Locating Exhaust Manifold Heat Insulator Bolts
      G05152769Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL NO. 1 MANIFOLD STAY 
    1. Temporarily install the manifold stay with the 2 bolts.
    2. Tighten the 2 bolts in the order shown in the illustration.

      Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 

      Fig 5: Locating Manifold Stay Bolts
      G05638065Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH 
    1. Install a new gasket to the cylinder head and a new gasket to the No. 3 air tube.

      HINT:

      • Install the exhaust manifold gasket with the gasket tab facing toward the rear of the engine.
      • Install the air tube gasket with the gasket claws facing the tube side.
        Fig 6: Identifying Air Tube And Gasket Claws
        G05638066Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Temporarily install the exhaust manifold with the 2 nuts labeled A and 8 new nuts.
    3. Uniformly tighten the nuts that are not labeled A, and then tighten the 2 nuts labeled A.

      Torque: 

      for nut A 

      10 N*m (102 kgf*cm, 7 ft.*lbf) 

      except nut A 

      21 N*m (214 kgf*cm, 15 ft.*lbf) 

      Fig 7: Locating Exhaust Manifold Nuts
      G05638067Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Install the heat insulator with the 3 bolts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      Fig 8: Locating Exhaust Manifold Heat Insulator Bolts
      G05152767Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL NO. 2 MANIFOLD STAY 
    1. Temporarily install the manifold stay with the 2 bolts.
    2. Tighten the 2 bolts in the order shown in the illustration.

      Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 

      Fig 9: Locating No. 2 Manifold Stay With Bolts
      G05638069Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL PROPELLER SHAFT HEAT INSULATOR 
    1. Install the heat insulator with the 2 bolts.

      Torque: 16 N*m (160 kgf*cm, 12 ft.*lbf) 

  8. INSTALL FRONT EXHAUST PIPE ASSEMBLY  (See INSTALLATION  )
  9. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY  (See INSTALLATION  )
  10. INSTALL CENTER EXHAUST PIPE ASSEMBLY  (See INSTALLATION  )
    Fig 10: Locating Propeller Shaft Heat Insulator Bolts
    G05638053Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL TAILPIPE ASSEMBLY  (See INSTALLATION  )
  12. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE 
    1. Apply a light coat of engine oil to a new O-ring.
    2. Install the O-ring to the guide.
    3. Install the dipstick guide with the bolt.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

    4. Install the dipstick.
    Fig 11: Locating Dipstick Guide Bolt
    G05628421Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSPECT FOR EXHAUST GAS LEAK 
  14. INSTALL FRONT FENDER APRON SEAL FRONT LH 
    1. Install the fender apron seal with the 4 clips.
      Fig 12: Identifying Front Fender Apron Seal Clips (Front LH)
      G05759811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL FRONT FENDER APRON SEAL REAR LH 
    1. Install the fender apron seal with the 4 clips.
      Fig 13: Identifying Front Fender Apron Seal Clips (Rear LH)
      G05638052Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL FRONT FENDER APRON SEAL FRONT RH 
    1. Install the fender apron seal with the 3 clips.
      Fig 14: Identifying Fender Apron Seal Clips (Front RH)
      G05638049Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL FRONT FENDER APRON SEAL REAR RH 
    1. Install the fender apron seal with the 4 clips.
      Fig 15: Identifying Fender Apron Seal Clips (Rear RH)
      G05638050Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL NO. 2 ENGINE UNDER COVER 
    1. Install the No. 2 engine under cover with the 2 bolts.

      Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 

      Fig 16: Locating No. 2 Engine Under Cover Bolts
      G05628412Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY 
    1. Install the No. 1 engine under cover with the 10 bolts.

      Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 

      Fig 17: Locating No. 1 Engine Under Cover Bolts
      G05628411Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH  (See INSTALLATION )
  21. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH  (See INSTALLATION )
  22. INSTALL UPPER RADIATOR SUPPORT SEAL  (See INSTALLATION )
  23. INSTALL ENGINE ROOM SIDE COVER RH  (See INSTALLATION )
  24. INSTALL ENGINE ROOM SIDE COVER LH  (See INSTALLATION )
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