Toyota 17104-50220
Exhaust Manifold, Passenger Side

Start by clearing the Way of the No. 1 Engine Under Cover and conducting an engine coolant drain. The worker must remove the throttle body cover sub-assembly and sequentially remove the air cleaner hose assembly and air cleaner assembly. Both front fender apron seal rear LH and front fender apron seal LH need removal through clip removal of five and six pieces respectively. Once the manufacturing process for the exhaust manifold has begun first uninstall the Bank 1 No. 2 air hose and No. 3 air tube as well as the Bank 1 air switching valve assembly. The installation requires a complete repetition for both the front fender apron seal rear RH and front fender apron seal RH. Start by unscrewing the clip on the No. 5 water bypass hose then disconnect the heater outlet water hose together with the engine oil level dipstick guide. You must remove the water by-pass pipe assembly after disconnecting the 2 water hoses from the transmission oil cooler and removing 3 bolts. The service professional should disconnect the No. 2 air injection system hose and remove both the No. 2 air tube and air switching valve assembly for Bank 2. For the first step remove the front exhaust pipe assembly and then continue to the following step which requires removal of propeller shaft heat insulator and front propeller shaft assembly (4WD models only). The front No. 2 exhaust pipe assembly should be removed first before removing the No. 1 exhaust manifold heat insulator by detaching 4 bolts. Proceed with the removal of exhaust manifold sub-assembly RH by unfastening 8 nuts together with the gasket while also removing the No. 2 exhaust manifold heat insulator using 4 bolts before completing the procedure by taking off 8 nuts on the exhaust manifold sub-assembly LH along with its gasket.

Set the new gasket on the cylinder head LH with the oval side facing backward before installing the exhaust manifold by using six fresh nuts that require 21 Nm (214 kgf-cm, 15 ft-lbf) torque. The next step involves implementing the No. 2 exhaust manifold heat insulator through 3 bolts which need torquing to 8.5 Nm (87 kgf-cm, 75 in-lbf). The installation of the exhaust manifold begins with inserting the new gasket onto the cylinder head RH side with the oval facing forward while paying attention to the correct orientation then tightening 6 new nuts to 21 Nm (214 kgf-cm, 15 ft-lbf). Proceed with installing the front exhaust pipe assembly and then continue with front No. 2 exhaust pipe assembly installation for the Regular Cab Standard Deck, after which install the front No. 2 exhaust pipe assembly that excludes the Standard Deck Regular Cab models. The technician should install the air switching valve assembly. Complete the installation by connecting the cable to the negative battery terminal although some systems demand system initialization after the reconnection process.

Service and repair of the 1GR-FE exhaust manifold starts with disconnecting the negative battery cable and requiring several systems to perform an initialization after reconnecting. Start by removing the air switching valve assembly before moving on to the front No.2 exhaust pipe assembly (Regular Cab Standard Deck) followed by other versions of the model except standard deck regular cab. Move forward to take off the front exhaust pipe assembly. Right-hand exhaust manifold removal requires you to separate each of its six nuts, exhaust manifold along with its accompanying gasket. To detach the No. 2 exhaust manifold heat insulator you need to unscrew its three bolts and separate the heat insulator component. The removal sequence ends with disassembling the exhaust manifold on the left-hand side by disconnecting 6 nuts followed by exhausting its components.

Remove the front fender apron seal LH by taking out 6 clips.

Temporarily install the No. 1 exhaust manifold heat insulator with 4 bolts and tighten them to 7.5 Nm (76 kgf-cm, 66 in-lbf).

Unscrew the 3 bolts and remove the heat insulator.

Remove the air switching valve assembly, followed by the front No. 2 exhaust pipe assembly for Regular Cab Standard Deck or the alternative version, and then the front exhaust pipe assembly.

Set a new gasket on the cylinder head with the oval shape facing forward and secure it with 6 new nuts, torqued to 21 Nm (214 kgf-cm, 15 ft-lbf).