Toyota 25051-0V070
Exhaust Manifold

The installation of an exhaust manifold begins with installing the No. 1 manifold converter insulator that requires 4 bolts with 12 Nm (122 kgf-cm, 9 ft-lbf) torque. Place a new gasket onto the cylinder head while installing the exhaust manifold converter temporarily using 5 nuts that need to be tightened in the specified sequence to 35 Nm (357 kgf-cm, 26 ft-lbf). You should start with No. 2 exhaust manifold heat insulator installation using two bolts that require 12 Nm torque (122 kgf-cm or 9 ft-lbf) before adding four bolts to the No. 1 exhaust manifold heat insulator at the same torque rate. Coat the No. 2 manifold stay with a bolt along with a nut that requires 43 Nm (438 kgf-cm, 32 ft-lbf) torque followed by another bolt using a nut torqued at the same strength. Integrate the air fuel ratio sensor (for Bank 1 Sensor 1) along with the radiator hose clamp as well as the engine oil level dipstick guide and the engine oil level dipstick. When inspecting the front exhaust pipe compression spring with a vernier caliper check its free length surpasses 41.5 mm (1.63 in.) otherwise replace the component. The surface requires cleaning with a wire brush before adding new gaskets that face the exhaust manifold converter while maintaining its correct position yet eliminating the use of any old gaskets. A fresh gasket follows to cover the front exhaust pipe's surface. Use 2 compression springs and 4 bolts to mount the front exhaust pipe along with torqueing bolt A and bolt B at 43 Nm pressure (438 kgf-cm, 32 ft-lbf). Finally, connect the heated oxygen sensor connector. Complete the task by setting up the generator assembly while checking for exhaust gas leaks throughout the system.

The removal process for an exhaust manifold on a 2AR-FE engine requires the generator assembly as the first step. The removal procedure begins with disconnected heated oxygen sensor and bolted-out 4 fasteners which results in removing both front exhaust pipe and two compression springs and exhaust manifold converter gaskets. The maintenance requires extraction of both the engine oil level dipstick and its guide. The radiator hose clamp requires uninstallation before moving forward. During the replacement process remove the air fuel ratio sensor from its location for Bank 1 Sensor 1. You begin with step one which includes removing the manifold stay by uninstalling its bolt along with nut and stay until completion of the first step. Step two follows to perform the process on the No. 2 manifold stay with identical procedures. You need to take out the 4 bolts of the No. 1 exhaust manifold heat insulator before you can remove the No. 2 exhaust manifold heat insulator by removing its 2 bolts. The procedure requires removing the 5 nuts in sequence from the exhaust manifold converter sub-assembly and afterwards removing the converter and gasket before removing the No. 1 manifold converter insulator using its bolts and insulator.