Toyota Celica 1994-1998 Repair Guide

Exhaust Manifold

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REMOVAL & INSTALLATION



5S-FE Engine
  1. Turn the ignition key to the OFF position. Disconnect the negative battery cable. Wait at least 90 seconds from the time the negative battery was disconnected to start work.
  2.  


CAUTION
Work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative battery cable has been disconnected. The SRS is equipped with a back-up power source so that if work is started within 90 seconds of disconnecting the negative battery cable, the SRS may deploy. When the negative terminal cable is disconnected from the battery, memory of the clock and radio will be canceled. Before you start working, make a note of the contents memorized by the audio memory system. When you have finished working, reset the audio systems and adjust the clock. Never use a back-up power supply from outside the vehicle.

  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. Remove the upper manifold heat insulator by removing the retaining bolts.
  8.  
  9. Remove the two manifold stays.
  10.  
  11. Remove the six nuts and lower the exhaust manifold. Discard the nuts and replace with new ones.
  12.  
  13. Remove the four bolts and lift off the lower heat insulator.
  14.  
  15. To separate the exhaust manifold from the converter, proceed as follows:
    1. Remove the 5 bolts and the lower heat insulator.
    2.  
    3. Remove the 8 bolts and 2 converter heat insulators.
    4.  
    5. Remove the 3 bolts, 2 nuts, converter, gasket, retainer and cushion.
    6.  

  16.  
  17. 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.
  18.  

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. Then 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.  
  5. 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.  

  6.  
  7. 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.
  8.  
  9. Lower the vehicle and connect the negative battery cable.
  10.  
  11. Start the engine and inspect for leaks.
  12.  
  13. Reset any electronic components such as the radio.
  14.  

7A-FE Engine

See Figures 1, 2, 3, 4, 5, 6 and 7

  1. Disconnect the negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Working from under the vehicle, remove the bolts holding the front exhaust pipe to the mounting bracket.
  6.  
  7. Using a 14mm deep socket wrench, remove the nuts and the gasket and disconnect the front exhaust pipe from the manifold.
  8.  

  1. Remove the main oxygen sensor connector.
  2.  
  3. Remove the bolts and extract upper heat insulator.
  4.  



Click image to see an enlarged view

Fig. Fig. 1: Remove the four bolts holding the heat shield-7A-FE engine shown

  1. Remove the nuts, exhaust manifold, and the gasket.
  2.  



Click image to see an enlarged view

Fig. Fig. 2: Remove the heat shield to expose the exhaust manifold



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Fig. Fig. 3: Note the exhaust manifold is bolted to the side of the cylinder head

  1. Remove the bolts and lower heat insulator from the exhaust manifold.
  2.  



Click image to see an enlarged view

Fig. Fig. 4: The manifold is heavy, use care when removing



Click image to see an enlarged view

Fig. Fig. 5: Pull off the old gasket material from the head ...



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Fig. Fig. 6: ... use a coarse cloth to remove any rust or dirt on the head ...



Click image to see an enlarged view

Fig. Fig. 7: ...and the manifold

To install:
  1. Install the lower heat insulator to the exhaust manifold with the bolts and tighten to 82 inch lbs. (9 Nm).
  2.  
  3. Install a new gasket and the exhaust manifold with the nuts. Uniformly tighten the nuts in several passes. Tighten the nuts to 25 ft. lbs. (34 Nm).
  4.  
  5. Install the upper heat insulator with the bolts and tighten to 82 inch lbs. (9 Nm).
  6.  
  7. Install the front exhaust pipe with a new gasket to the exhaust manifold. Install the nuts using a 14mm deep socket wrench. Tighten the nuts to 46 ft. lbs. (62 Nm).
  8.  
  9. Secure the front exhaust pipe to the exhaust pipe bracket with the bolts.
  10.  
  11. Connect the main oxygen sensor connector.
  12.  
  13. Lower the vehicle safely and reconnect the negative battery cable.
  14.  
  15. Start the engine and make sure that there are no exhaust leaks.
  16.  

 
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