Avalon 1995-1996

Exhaust Manifold

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Remove the engine undercovers from the vehicle.
  8.  
  9. From below the engine, disconnect the front exhaust pipe from the exhaust manifold by removing the nuts.

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    Fig. Front exhaust manifold-to-front pipe mounting nut locations



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    Fig. Rear exhaust manifold-to-front pipe mounting



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    Fig. Lower the exhaust pipe from the front and rear exhaust manifolds

  10.  
  11. If necessary, lower the vehicle to access the top of the engine.
  12.  
  13. Remove the Exhaust Gas Recirculation (EGR) pipe from the exhaust manifold by removing the nuts.
  14.  
  15. Remove the right-hand exhaust manifold:
    1. Disconnect the heated oxygen sensor connector.
    2.  
    3. Remove the bolt, nut and exhaust manifold stay.
    4.  
    5. Remove the 6 nuts, exhaust manifold and gasket.

      Click image to see an enlarged view

      Fig. Remove the right-hand exhaust manifold

    6.  

  16.  
  17. Remove the left-hand exhaust manifold:
    1. Disconnect the heated oxygen sensor connector.
    2.  
    3. Remove the bolt, nut and exhaust manifold stay.
    4.  
    5. Remove the 6 nuts, exhaust manifold and gasket.

      Click image to see an enlarged view

      Fig. Remove the left-hand exhaust manifold



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      Fig. Front exhaust manifold retaining nut locations



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      Fig. There is a stay on the left side of the front manifold to be removed



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      Fig. Remove the exhaust manifold and discard the old gasket



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      Fig. Always discard old exhaust gaskets

    6.  

  18.  

To install:

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Fig. Always scrape old materials from the cylinder head



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Fig. . . . and manifold prior to installation

  1. Install the right-hand exhaust manifold:
    1. Install a new gasket and the exhaust manifold with the 6 nuts. Uniformly tighten the nuts in several passes to 36 ft. lbs. (49 Nm).
    2.  
    3. Install the exhaust manifold stay with the bolt and nut. Alternately tighten the bolt and nut to 15 ft. lbs. (20 Nm).
    4.  
    5. Connect the heated oxygen sensor connector.
    6.  

  2.  
  3. Using new gaskets, install the EGR pipe to the exhaust manifold and the engine. Tighten the 4 nuts to 108 inch lbs. (12 Nm).
  4.  
  5. Install the left-hand exhaust manifold:
    1. Install a new gasket and the exhaust manifold with the 6 nuts. Uniformly tighten the nuts in several passes to 36 ft. lbs. (49 Nm).
    2.  
    3. Install the exhaust manifold stay with the bolt and nut. Alternately tighten the bolt and nut to 15 ft. lbs. (20 Nm).
    4.  
    5. Connect the heated oxygen sensor connector.
    6.  

  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Connect the front exhaust pipe to the exhaust manifold. Use a new gasket and tighten the nuts to 46 ft. lbs. (62 Nm).
  10.  
  11. Install the engine undercovers to the vehicle.
  12.  
  13. Lower the vehicle.
  14.  
  15. Connect the negative battery cable.
  16.  

 
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