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Toyota 4Runner 2001-06

Exhaust Manifold

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Removal & Installation




CAUTION
When working on or around an exhaust manifold, make certain all surfaces are cool to the touch before beginning to work.


CAUTION
When working on or around an exhaust manifold, make certain all surfaces are cool to the touch before beginning to work.

1gr-FE Engine
Left Side
  1. Disconnect the exhaust crossover pipe from the exhaust manifold by removing the 3 nuts.
  2.  
  3. Remove the exhaust manifold heat insulator.
  4.  
  5. Disconnect the exhaust manifold from the manifold brace.
  6.  
  7. Remove the exhaust manifold and gasket.
  8.  

To install:

  1. Install a new gasket to the cylinder head with the oval shape facing the rear. Install the exhaust manifold and tighten the nuts evenly, in several steps, to 22 ft. lbs. (30 Nm).
  2.  
  3. Install the manifold brace and tighten the bolts to 30 ft. lbs. (40 Nm).

    Click image to see an enlarged view

    Fig. Correct exhaust manifold gasket position-4.0L engine, left side

  4.  
  5. Install the exhaust heat insulator. Tighten the nuts to 71 inch lbs. (8 Nm).
  6.  
  7. Connect the crossover pipe to the exhaust manifold, using a new gasket. Tighten the nuts to 46 ft. lbs. (62 Nm).
  8.  
  9. Start the engine and check for exhaust leaks.
  10.  

Right Side
  1. Remove the transmission dipstick/filler tube.
  2.  
  3. Disconnect the exhaust crossover pipe from the exhaust manifold by removing the 3 nuts.
  4.  
  5. Remove the exhaust manifold heat insulator (shield).
  6.  
  7. Disconnect the exhaust manifold from the manifold brace.
  8.  
  9. Disconnect the oxygen sensor connector.
  10.  
  11. Remove the exhaust manifold and gasket.
  12.  

To install:

  1. Install a new gasket to the cylinder head with the oval shape facing forward. Install the exhaust manifold and tighten the nuts evenly, in several steps, to 22 ft. lbs. (30 Nm).
  2.  
  3. Install the manifold brace and tighten the bolts to 30 ft. lbs. (40 Nm).

    Click image to see an enlarged view

    Fig. Correct exhaust manifold gasket position-4.0L engine, right side

  4.  
  5. Install the exhaust heat insulator. Tighten the nuts to 71 inch lbs. (8 Nm).
  6.  
  7. Connect the crossover pipe to the exhaust manifold, using a new gasket. Tighten the nuts to 46 ft. lbs. (62 Nm).
  8.  
  9. Install the transmission filler tube and tighten the bolt to 9 ft. lbs. (12 Nm).
  10.  
  11. Start the engine and check for exhaust leaks.
  12.  

2RZ-FE & 3RZ-FE Engines


Click image to see an enlarged view

Fig. The exhaust pipe must be disconnected from the manifold and its mounting bracket-2RZ-FE and 3RZ-FE engines



Click image to see an enlarged view

Fig. Remove the nuts indicated to remove the exhaust manifold-2RZ-FE and 3RZ-FE engines

  1. Raise and safely support the vehicle.
  2.  
  3. Disconnect the front exhaust pipe from the manifold and mounting bracket.
  4.  
  5. Lower the vehicle.
  6.  
  7. Remove the heat insulator.
  8.  
  9. Remove the exhaust manifold and gasket.
  10.  

To install:

  1. Install the exhaust manifold and gasket to the engine; tighten the nuts to 36 ft. lbs. (49 Nm).
  2.  
  3. Attach the heat insulator, tighten the bolts and nuts to 48 inch lbs. (5 Nm).
  4.  
  5. Raise and support the vehicle.
  6.  
  7. Install the front exhaust pipe to the manifold with new gaskets. Apply a gasket to the front pipe, install the nuts and tighten to 46 ft. lbs. (62 Nm).
  8.  
  9. Attach the support bracket, tighten to 29 ft. lbs. (39 Nm).
  10.  
  11. Attach the clamp and tighten to 14 ft. lbs. (19 Nm).
  12.  
  13. Lower the vehicle.
  14.  
  15. Start the engine and check for exhaust leaks.
  16.  

2UZ-FE Engine


Click image to see an enlarged view

Fig. Exhaust manifold arrangement and gasket markings-4.7L (2UZ-FE) Engine


NOTE
The gaskets between the manifold and head and between the manifold and front exhaust pipe are not reusable. Toyota also specifies that the mounting nuts be replaced.

  1. Disconnect the negative battery cable.
  2.  
  3. Apply penetrating oil to the nuts and bolts, as required.
  4.  
  5. Remove the nuts from the front pipe that connects the manifold to the three-way catalytic converter
  6.  
  7. Detach the oxygen sensor electrical connector.
  8.  
  9. Remove the small bolts that hold the heat insulator to the manifold.
  10.  
  11. Remove the eight nuts and separate the manifold from the cylinder head. Discard the gasket.
  12.  

To install:

  1. Installation is the reverse of the removal process. Examine the replacement exhaust manifold-to-head gasket. Original equipment Toyota gaskets should have white paint marks on them. The white painted marks should face the manifold side. Use care to install the gasket in the correct direction.
  2.  
  3. Using a new gasket, install the manifold using care to align the studs with the front pipe. A new gasket between the manifold outlet and the front pipe is also required. Use new service replacement nuts. Uniformly tighten the nuts to 33 ft. lbs. (44 Nm).
  4.  
  5. Install the heat insulator and tighten the four bolts to 66 inch lbs. (7.5 Nm).
  6.  
  7. Tighten the manifold-to-front pipe nuts to 46 ft. lbs. (62 Nm).
  8.  
  9. Connect the negative battery cable, start the engine and verify no exhaust leaks.
  10.  

5VZ-FE Engine


Click image to see an enlarged view

Fig. Exhaust manifolds and related parts-3.4L engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Exhaust crossover pipe, from the exhaust manifold by removing the 3 nuts
     
    Exhaust Gas Recirculation (EGR) pipe, from the exhaust manifold, on the left manifold equipped with an EGR valve
     
    Exhaust manifold heat insulator, by removing the 3 nuts
     
    Exhaust manifold
     

  4.  


    Click image to see an enlarged view

    Fig. Exhaust crossover pipe mounting nut locations-3.4L engine



    Click image to see an enlarged view

    Fig. Exhaust manifold nuts-3.4L engine


To install:

  1. Install or connect the following:

    Exhaust manifold, using a new gasket. Tighten the nuts to 30 ft. lbs. (40 Nm).
     
    Exhaust heat insulator. Tighten the nuts to 71 inch lbs. (8 Nm).
     
    EGR pipe to the exhaust manifold, if equipped with an EGR valve. Tighten the manifold nuts to 14 ft. lbs. (18 Nm) and the clamp nuts to 71 inch lbs. (8 Nm).
     
    Crossover pipe to the exhaust manifold, using a new gasket. Tighten the nuts to 33 ft. lbs. (45 Nm).
     

  2.  

Left Side


Click image to see an enlarged view

Fig. Exhaust manifold arrangement-3.4L (5VZ-FE) Engine



Click image to see an enlarged view

Fig. Removing the bolts securing the crossover pipe to the manifolds-3.4L (5VZ-FE) Engine



Click image to see an enlarged view

Fig. Exhaust manifold retaining nut locations-3.4L (5VZ-FE) Engine

  1. Disconnect the exhaust crossover pipe and gaskets from the exhaust manifold.
  2.  
  3. Remove the heat insulator (shield) from the manifold.
  4.  
  5. Unfasten the retainers, then remove the manifold.
  6.  

To install:

  1. Install the exhaust manifold to the engine with a new gasket. Tighten the nuts to 30 ft. lbs. (40 Nm).
  2.  
  3. Install the heat insulator, tighten the nuts down to 71 inch lbs. (8 Nm).
  4.  
  5. Attach the crossover pipe to the exhaust manifold, tighten the nuts to 33 ft. lbs. (45 Nm).
  6.  

Right Side
  1. Disconnect the exhaust crossover pipe from the exhaust manifold.
  2.  
  3. Remove the exhaust manifold heat insulator.
  4.  
  5. Unfasten the six nuts securing the manifold, then remove the manifold from the engine.
  6.  

To install:

  1. Install the exhaust manifold with the new gasket; tighten the six nuts to 30 ft. lbs. (40 Nm).
  2.  
  3. Attach the heat insulator, tighten the nuts to 71 inch lbs. (8 Nm).
  4.  
  5. Connect the crossover pipe with a new gasket, to the exhaust manifold. Tighten the nuts to 33 ft. lbs. (45 Nm).
  6.  

 
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