Toyota Celica 1986-1993 Repair Guide

Exhaust Manifold

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REMOVAL & INSTALLATION




WARNING
Make sure all wire, hoses and vacuum lines are marked to simplify installation. When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.


CAUTION
On models with an air bag, wait at least 30 seconds from the time that the ignition switch is turned to the lock position and the battery is disconnected before performing any further work.

2S-E Engine
  1. Disconnect the negative battery cable. Raise the vehicle and support it safely as necessary. Remove the right hand gravel shield from beneath the engine.
  2.  
  3. Remove the exhaust pipe support bracket. Unfasten the bolts (soak bolts with penetrating oil or equivalent) from the flange and detach the exhaust pipe from the manifold.
  4.  
  5. Remove the air cleaner stove hoses from the exhaust manifold, if so equipped. Remove the egr valve, if so equipped.
  6.  
  7. Remove, or move aside, any of the air injection system components which may be in the way when removing the manifold.
  8.  
  9. Remove the exhaust manifold retaining bolts, in two or three stages, starting from the inside, working out. Remove the exhaust manifold from the vehicle.
  10.  

To Install:

  1. Install the exhaust manifold to the engine block. Use a new gasket, as required. Tighten the exhaust manifold retaining bolts from the center to the ends in steps to 31 ft. lbs. (42 Nm).
  2.  
  3. Install all air injection components. Install the egr valve.
  4.  
  5. Install the air cleaner stove hoses to the exhaust manifold, if so equipped.
  6.  
  7. Install the exhaust pipe and brackets (stays) to the exhaust manifold (use new exhaust pipe gaskets as required).
  8.  
  9. Install gravel shield and reconnect the battery cable. Start engine and check for exhaust leaks.
  10.  

3S-GE and 3S-GTE Engines
  1. Disconnect the negative battery cable. Raise and support the vehicle safely as necessary. Remove the right hand gravel shield from underneath the car.
  2.  
  3. Remove the exhaust pipe support stay. Unbolt (soak bolts with penetrating oil or equivalent) the exhaust pipe from the exhaust manifold flange.
  4.  
  5. Disconnect the oxygen sensor connector. On the 3S-GE engine, remove the upper heat insulator.
  6.  
  7. Remove the manifold retaining bolts. Remove the exhaust manifold from the vehicle.

    Click image to see an enlarged view

    Fig. Fig. 1 Exhaust manifold installation3S-GTE engine shown

  8.  
  9. Installation is the reverse of the removal procedure. Use a new gasket on exhaust manifold and exhaust pipe as required. Torque all retaining nuts and bolts evenly working from the center to the ends in steps to 32 ft. lbs. (43 Nm) on the 3S-GE engine and 38 ft. lbs. (52 Nm) on the 3S-GTE engine. Reconnect the battery cable. Start engine and check for exhaust leaks.
  10.  

3S-FE and 5S-FE Engines
  1. Disconnect the negative battery cable. Remove the exhaust manifold heat insulator shield assembly.
  2.  
  3. Remove the necessary components in order to gain access to the exhaust manifold retaining bolts.

    Click image to see an enlarged view

    Fig. Fig. 2 Exhaust manifold installation5S-FE engine shown

  4.  
  5. Disconnect the exhaust manifold bolts (soak bolts with penetrating oil or equivalent) at the exhaust pipe. It may be necessary to raise and support the vehicle safely before removing these bolts.
  6.  
  7. Remove the exhaust manifold retaining bolts. Remove the exhaust manifold from the vehicle.
  8.  

To Install:

  1. Installation is the reverse of the removal procedure. Use a new gasket on exhaust manifold and exhaust pipe as required. Torque all retaining nuts and bolts evenly working from the center to the ends in steps to 29 ft. lbs. (39 Nm) on the 3S-FE engine and 36 ft. lbs. (49 Nm) on the 5S-FE engine. Reconnect the battery cable. Start engine and check for exhaust leaks.
  2.  

4A-FE Engine
  1. Disconnect the negative battery cable. Raise and support the vehicle safely as necessary. Remove the right hand gravel shield from underneath the car.
  2.  
  3. Remove the exhaust pipe support stay. Unbolt (soak bolts with penetrating oil or equivalent) the exhaust pipe from the exhaust manifold flange.
  4.  
  5. Disconnect the oxygen sensor connector. Remove the upper heat insulator.
  6.  
  7. Remove the manifold retaining bolts. Remove the exhaust manifold from the vehicle.
  8.  

To Install:

  1. Installation is the reverse of the removal procedure. Use a new gasket on exhaust manifold and exhaust pipe as required. Torque all retaining nuts and bolts evenly working from the center to the ends in steps to 18 ft. lbs. (25 Nm). Reconnect the battery cable. Start engine and check for exhaust leaks.
  2.  

 
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