Toyota Camry 1983-1996 Repair Guide

Exhaust Manifold

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REMOVAL & INSTALLATION



1C-LTC and 2-CT Engines

See Figure 1

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the turbocharger from the exhaust manifold.
  4.  
  5. Remove the heat insulator from the exhaust manifold by removing the two bolts.
  6.  



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Fig. Fig. 1: Removing the exhaust manifold and heat insulator

  1. Remove the exhaust manifold from the engine by removing the six bolts and two nuts.
  2.  

To install:
  1. Remove the exhaust manifold gasket and replace it with a new one.
  2.  
  3. Thoroughly clean the exhaust manifold and cylinder block to remove any carbon or gasket material deposits. If the carbon deposits are not removed, there is the possibility of them entering the turbine and causing damage.
  4.  
  5. Place the new gasket onto the manifold and install the exhaust manifold onto the engine with the six bolts. Tighten the bolts in an alternate pattern to 31 ft. lbs. (42 Nm).
  6.  
  7. Install the heat insulator onto the manifold and secure with the two bolts.
  8.  
  9. Install the turbocharger.
  10.  
  11. Connect the negative battery cable. Start the engine and inspect for leaks.
  12.  

2S-ELC Engines

CAUTION
Be careful when working on or near the catalytic converter. External temperatures can reach 1,500°F (816°C) and more causing severe burns. Removal and installation of the exhaust manifold should be accomplished only on a cold engine.

  1. Disconnect the negative battery cable.
  2.  
  3. Raise the front of the vehicle and support safely.
  4.  
  5. Disconnect the oxygen sensor wiring (USA only). The oxygen sensor is located in the exhaust manifold.
  6.  
  7. Loosen the front and rear flange bolts of the catalytic converter so that they can be turned by hand (there are two nuts and bolts per flange).
  8.  
  9. Support the catalytic converter and disconnect the exhaust pipe by removing the loosened flange bolts and nuts. Remove the flange gaskets and set them aside.
  10.  
  11. Remove the exhaust pipe stay bolts from the cylinder block.
  12.  
  13. Remove the three nuts from the exhaust manifold flange.
  14.  
  15. Disconnect the exhaust pipe from the manifold and remove the two exhaust manifold gaskets. You may have to "coax'' the manifold from the block with a few sharp blows from a heavy rubber mallet. Remove the two exhaust manifold gaskets.
  16.  


WARNING
When removing the exhaust manifold, be careful not to damage the oxygen sensor.

  1. With a brush and solvent, thoroughly clean the surfaces of the exhaust manifold and cylinder block to remove any carbon or gasket material residue. While you are in the area, run a wire brush across the converter flange also. If the converter flange gaskets are damaged, replace them with new ones.
  2.  

To install:
  1. Lay the two new gaskets onto the exhaust manifold and attach the manifold to the cylinder block with the three nuts. Tighten the manifold nuts to 31 ft. lbs. (42 Nm).
  2.  
  3. Attach the exhaust manifold stay to the cylinder block with the two bolts.
  4.  
  5. Support the converter and install the flange gaskets and nuts and bolts. Tighten the front and rear flange bolts to 32 ft. lbs. (43 Nm).
  6.  
  7. Connect the oxygen sensor wiring (USA only).
  8.  
  9. Lower the vehicle and connect the negative battery cable.
  10.  
  11. Start the engine and inspect for exhaust leaks.
  12.  

3S-FE Engines

See Figures 2, 3, 4 and 5


CAUTION
Be careful when working on or near the catalytic converter. External temperatures can reach 1,500°F (816°C) and more causing severe burns. Removal and installation of the exhaust manifold should be accomplished only on a cold engine.

  1. Raise the front of the vehicle and support safely.
  2.  
  3. Disconnect the oxygen sensor wiring.
  4.  
  5. Loosen the bolt and disconnect the clamp from the catalytic converter bracket. Remove the nuts and disconnect the exhaust pipe from the catalytic converter. Remove the gasket and discard it.
  6.  
  7. Remove the upper manifold heat insulator by removing the six retaining bolts.
  8.  
  9. Remove the six nuts and lower the exhaust manifold and catalytic converter assembly. Discard the nuts and replace with new.
  10.  



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Fig. Fig. 2: Remove the exhaust manifold heat shield retaining bolts

  1. Disconnect the catalytic converter stay by removing the two bolts and two nuts.
  2.  
  3. To separate the exhaust manifold from the converter, proceed as follows:
    1. Unbolt the five lower manifold heat insulator bolts.
    2.  
    3. Remove the catalytic converter heat insulator bolts.
    4.  
    5. Unbolt and separate the exhaust manifold from the catalytic converter.
    6.  
    7. Remove the gasket, retainer and cushion.
    8.  

  4.  
  5. Thoroughly clean the exhaust manifold and cylinder block to remove any carbon or gasket material deposits. Replace the two exhaust manifold gaskets, catalytic converter gasket, retainer and cushion.
  6.  



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Fig. Fig. 3: Separating the converter heat insulators from the exhaust manifold



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Fig. Fig. 4: Separating the catalytic converter from the exhaust manifold

To install:
  1. Attach the two converter heat insulators with the eight bolts. Place the new cushion, retainer and gasket on the converter. Position the converter onto the exhaust manifold and install the three bolts and two nuts. Tighten the nuts and bolts to 22 ft. lbs. (29 Nm).
  2.  
  3. Place a new gasket on the engine so that the R mark is facing the back (not all models will have this mark). If the gasket is not installed properly, it will not seal.
  4.  



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Fig. Fig. 5: Place the new gasket onto the engine with the letter R facing towards the back as shown for the intake manifold

  1. Support the exhaust manifold and catalytic converter assembly by hand and guide the assembly over the mounting studs. Install the six new nuts and tighten them to 31 ft. lbs. (41 Nm) on 1987-88 models , or 37 ft. lbs. (48 Nm) on 1989-91 models.
  2.  
  3. Install the converter stay with the two bolts and two nuts and tighten to 31 ft. lbs. (41 Nm).
  4.  
  5. Install the manifold upper heat insulator with the six bolts.
  6.  
  7. Place a new gasket onto the exhaust pipe and connect the exhaust pipe to the catalytic converter with the three nuts. Tighten the nuts to 46 ft. lbs. (62 Nm). Install the clamp and the clamp bolt.
  8.  
  9. Attach the oxygen sensor connector.
  10.  
  11. Lower the vehicle and connect the negative battery cable.
  12.  
  13. Start the engine and inspect for leaks.
  14.  

5S-FE Engines

See Figures 6, 7, 8, 9 and 10

  1. Raise the front of the vehicle and support safely.
  2.  
  3. Disconnect the oxygen sensor wiring.
  4.  
  5. Loosen the two bolts and disconnect the front exhaust pipe bracket. Disconnect the exhaust pipe from the catalytic converter. Remove the gasket and discard it.
  6.  
  7. On models except California perform the following:
    1. Remove the upper manifold heat insulator by removing the six retaining bolts.
    2.  
    3. Remove the two manifold stays.
    4.  
    5. Remove the six nuts and lower the exhaust manifold. Discard the nuts and replace with new ones.
    6.  
    7. Remove the four bolts and lift off the lower heat insulator.
    8.  

  8.  
  9. On California models perform the following:
    1. Remove the upper manifold heat insulator by removing the four retaining bolts.
    2.  
    3. Remove the two manifold stays.
    4.  
    5. Remove the six nuts and lower the exhaust manifold and catalytic converter assembly. Discard the nuts and replace with new ones.
    6.  

  10.  
  11. To separate the exhaust manifold from the converter, proceed as follows:
    1. Unbolt the lower manifold heat insulator (three bolts).
    2.  
    3. Unbolt the two catalytic converter heat insulators (eight bolts).
    4.  
    5. Unbolt and separate the exhaust manifold from the catalytic converter (three bolts and two nuts).
    6.  
    7. Remove the gasket, retainer and cushion.
    8.  

  12.  
  13. Thoroughly clean the exhaust manifold and cylinder block to remove any carbon or gasket material deposits. Replace the exhaust manifold gaskets, catalytic converter gasket, retainer and cushion.
  14.  

To install:
  1. To assemble the exhaust manifold to the converter on California models, attach these components in this order:
    1. Three-way catalytic converter
    2.  
    3. Cushion
    4.  
    5. Retainier
    6.  
    7. Gasket
    8.  
    9. Exhaust manifold
    10.  
    11. Bolts and nuts; tighten the nuts to 22 ft. lbs. (29 Nm).
    12.  
    13. Heat insulators
    14.  
    15. Eight bolts
    16.  
    17. Manifold lower heat insulator
    18.  
    19. Three bolts
    20.  

  2.  
  3. For California models, install a new gasket, the exhaust manifold and catalytic converter assembly with the six nuts. Uniformly tighten the nuts in several passes to 36 ft. lbs. (49 Nm).
    1. Install the manifold stay with the bolt and nut and tighten to 31 ft. lbs. (42 Nm). Install the No. 1 manifold stay and tighten to 31 ft. lbs. (42 Nm).
    2.  
    3. Install the manifold upper heat insulator with the four bolts and attach the two oxygen sensor wiring harnesses.
    4.  

  4.  



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Fig. Fig. 6: Assemble the exhaust manifold components in this order-5S-FE California engines



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Fig. Fig. 7: Assemble the exhaust manifold components in this order-5S-FE California engines continued

  1. On non-California models perform the following:
    1. Install the lower heat insulator with the four bolts securely.
    2.  
    3. Install a new gasket and attach the exhaust manifold with six new nuts, uniformly tighten them to 36 ft. lbs. (49 Nm).
    4.  
    5. Attach the manifold stay with the bolt and nut and tighten to 31 ft. lbs. (42 Nm).
    6.  
    7. Attach the No. 1 manifold stay and tighten that to 31 ft. lbs. (42 Nm).
    8.  
    9. Attach the manifold upper heat insulator with six new bolts and tighten them securely. Connect the oxygen sensor wiring.
    10.  

  2.  



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Fig. Fig. 8: Secure the lower heat insulator to the engine prior t manifold installation-5S-FE non California engines



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Fig. Fig. 9: Tighten the exhaust manifold in several passes-5S-FE non California engines



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Fig. Fig. 10: Install the upper heat shield and attach the sensor wiring-5S-FE non California engines

  1. Place a new gasket onto the exhaust pipe and attach the pipe. Tighten the nuts to 46 ft. lbs. (62 Nm). Install the clamp and the bracket.
  2.  
  3. Lower the vehicle and connect the negative battery cable.
  4.  
  5. Start the engine and inspect for leaks.
  6.  
  7. Reset any electronic components such as the radio.
  8.  

2VZ-FE Engines
  1. Raise the car, support it on safety stands and then remove the engine under covers.
  2.  
  3. Remove the lower suspension crossmember. Remove the two front exhaust pipe stay bolts. Disconnect the front pipe from the center pipe and remove the gasket. Loosen the three nuts and then remove the front pipe.
  4.  
  5. Remove the six nuts and two bolts and lift out the upper crossover pipe and its gaskets.
  6.  
  7. Disconnect the O 2 sensor at the right side manifold. Remove the three mounting nuts and lift off the outside heat insulator.
  8.  
  9. Remove the six nuts and lift off the right side manifold and gasket. Remove the bolt and pull off the inner insulator.
  10.  
  11. Loosen the two nuts and lift off the left side heat insulator. Remove the six nuts and lift off the left side manifold and gaskets.
  12.  

To install:
  1. Scrape the mating surfaces of all old gasket material.
  2.  
  3. Install the right inner heat insulator and then position the manifold with a new gasket. Tighten the nuts to 29 ft. lbs. (39 Nm). Install the outer insulator.
  4.  
  5. Use a new gasket and install the left manifold. Tighten the nuts to 29 ft. lbs. (39 Nm). Install the outer insulator.
  6.  
  7. Use new gaskets and install the crossover pipe. Tighten the six nuts to 29 ft. lbs. (39 Nm) and the two bolts to 25 ft. lbs. (34 Nm).
  8.  
  9. Install the front exhaust pipe and tighten the manifold-to-pipe nuts to 46 ft. lbs. (62 Nm). Tighten the pipe-to-converter nuts to 32 ft. lbs. (43 Nm).
  10.  
  11. Install the lower suspension cross member and tighten all bolts and nuts to 153 ft. lbs. (207 Nm).
  12.  
  13. Connect the O 2 sensor and then lower the car. Connect the battery cable.
  14.  

3VZ-FE Engines
  1. Raise the car, support it on safety stands and then remove the engine under covers.
  2.  
  3. Remove the two front exhaust pipe stay bolts. Disconnect the front pipe from the center pipe and remove the gasket. Loosen the three nuts and then remove the front pipe.
  4.  
  5. Disconnect the O 2 sensor at the right side manifold. Remove the three mounting nuts and lift off the outside heat insulator.
  6.  
  7. Remove the six nuts and lift off the right side manifold and gasket.
  8.  
  9. Loosen the two nuts and bolt and lift off the left side heat insulator. Remove the six nuts and lift off the left side manifold and gaskets.
  10.  

To install:
  1. Scrape the mating surfaces of all old gasket material.
  2.  
  3. Install the right manifold with a new gasket. Tighten the nuts to 29 ft. lbs. (39 Nm). Install the outer insulator.
  4.  
  5. Use a new gasket and install the left manifold. Tighten the nuts to 29 ft. lbs. (39 Nm). Install the outer insulator.
  6.  
  7. Install the front exhaust pipe and tighten the manifold-to-pipe nuts to 46 ft. lbs. (62 Nm). Tighten the pipe-to-converter nuts to 32 ft. lbs. (43 Nm).
  8.  
  9. Connect the O 2 sensor, install the under covers and then lower the car. Connect the battery cable.
  10.  

1MZ-FE Engines
FRONT MANIFOLD

See Figures 11, 12, 13, 14, 15, 16, 17, 18 and 19



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Fig. Fig. 11: Front exhaust manifold-to-front pipe mounting nut locations



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Fig. Fig. 12: Rear exhaust manifold-to-front pipe mounting



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Fig. Fig. 13: Lowering the exhaust pipe from the front and rear exhaust manifolds



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Fig. Fig. 14: Always discard old exhaust gaskets



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Fig. Fig. 15: Front exhaust manifold retaining nut locations



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Fig. Fig. 16: There is a stay on the left side of the front manifold to be removed

Removing the oil filter helps gain access to a lower bolt in the front exhaust manifold.

  1. Disconnect the negative battery cable from the battery.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the engine undercovers from the vehicle.
  6.  
  7. From below the engine, disconnect the front exhaust pipe from the exhaust manifolds by removing the nuts.
  8.  

Check for access to some of the manifold lower bolts, if so remove any possible.

  1. Lower the vehicle to access the upper manifold bolts.
  2.  
  3. Disconnect and remove the heated oxygen sensor.
  4.  
  5. Remove the exhaust manifold stay by removing the bolt and nut.
  6.  
  7. Remove the remaining nuts to the exhaust manifold and separate the exhaust manifold from the engine.
  8.  



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Fig. Fig. 17: Remove the exhaust manifold and discard the old gasket



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Fig. Fig. 18: Always scrape old materials from the cylinder head



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Fig. Fig. 19: ... and manifold prior to installation

To install:
  1. Using a new gasket, install the exhaust manifold to the engine and install the six nuts. Uniformly tighten the bolts to 36 ft. lbs. (49 Nm).
  2.  
  3. Install the exhaust manifold stay and install the bolt and nut. Tighten the bolt and nut to 15 ft. lbs. (20 Nm).
  4.  
  5. Attach the heated oxygen sensor to the exhaust manifold.
  6.  
  7. Raise the vehicle and safely support.
  8.  
  9. Attach the front exhaust pipe to the exhaust manifold. Use a new gasket and tighten the two 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 to the battery.
  16.  

REAR MANIFOLD
  1. Disconnect the negative battery cable from the battery.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the engine undercovers from the vehicle.
  6.  
  7. From below the engine, disconnect the front exhaust pipe from both exhaust manifolds.
  8.  
  9. Remove the EGR pipe from the rear exhaust manifold by removing the four nuts.
  10.  
  11. Disconnect the heated oxygen sensor wiring to the right exhaust manifold.
  12.  
  13. Remove the exhaust manifold stay by removing the bolt and nut.
  14.  
  15. Remove the six nuts to the exhaust manifold and separate the exhaust manifold from the engine.
  16.  

To install:
  1. Using a new gasket, install the exhaust manifold to the engine and install the six nuts. Uniformly tighten and then tighten the bolts to 36 ft. lbs. (49 Nm).
  2.  
  3. Install the exhaust manifold stay and install the bolt and nut. Tighten the bolt and nut to 15 ft. lbs. (20 Nm).
  4.  
  5. Attach the heated oxygen sensor wiring to the exhaust manifold.
  6.  
  7. Using new gaskets, install the EGR pipe to the exhaust manifold and the engine. Tighten the four nuts to 9 ft. lbs. (12 Nm).
  8.  
  9. Attach the front exhaust pipe to the exhaust manifold. Use a new gasket and tighten the two 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 to the battery.
  16.  

 
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