Question 1

How to install the exhaust manifold on Toyota Corolla?

Accepted Answer

Begin installing the exhaust manifold for 2ZR-FE by placing the No. 2 exhaust manifold heat insulator on its position and fastening it using 3 bolts whose torque should be 12 Nm (122 kgf-cm, 9 ft-lbf). Fasten the exhaust manifold using 5 new nuts then torque them to 21 Nm (214 kgf-cm, 16 ft-lbf). The manifold stay gets installed using 3 bolts with a torques setting of 43 Nm (439 kgf-cm, 32 ft-lbf). Use a vernier caliper to measure the compression springs inside the front exhaust pipe assembly for their free length because their minimum specification might indicate replacement. Use new gaskets to build exhaust manifold-to-front exhaust pipe connections by applying a plastic hammer and wooden block to push them tightly in but only put them in the right direction and avoid all reuses and damages. Use the 4 exhaust pipe supports to fix the front exhaust pipe assembly before tightening the 4 bolts with 4 compression springs to 43 Nm (440 kgf-cm, 32 ft-lbf) and hook the heated oxygen sensor connector. The No. 1 exhaust manifold heat insulator requires installation with four bolts experiencing 12 Nm (122 kgf-cm, 9 ft-lbf) torque. The next installation procedure involves connecting the air fuel ratio sensor and No. 2 cylinder head cover and outer cowl top panel (both TMC Made and non-TMC Made models). As part of the installation connect the windshield wiper motor and link assembly, cowl top ventilator louvers, hood to cowl top seal and both front wiper arm and blade assemblies while inspecting for exhaust gas leaks during the procedure.

Question 2

How to install the exhaust manifold on Toyota RAV4?

Accepted Answer

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.

Question 3

How to service and repair the exhaust manifold on Toyota Tundra?

Accepted Answer

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.

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