Toyota Celica, Corolla, ECHO & MR2 1999-05

Exhaust Manifold

Print

Removal & Installation



1NZ-FE Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    On vehicles equipped with an air bag, wait at least 90 seconds before proceeding after disconnecting the negative battery cable.



    Negative battery cable.
     



    All electrical wires and vacuum hoses that interfere with removal of the exhaust manifold.
     
    Exhaust heat insulator
     
    Exhaust pipe stay
     
    Exhaust pipe from the manifold by removing the 2 bolts and 2 compression springs.
     
    Exhaust manifold and gasket
     

  4.  

To install:

  1. Clean the gasket surfaces
  2.  
  3. Install or connect the following:

    Exhaust manifold with a new gasket. Bolts: 20 ft. lbs. (27 Nm).
     
    Exhaust stay to the engine and exhaust manifold. Bolt and nuts: 29 ft. lbs. (40 Nm).
     
    Exhaust manifold heat insulator. Bolts: 71 inch lbs. (8 Nm).
     
    Exhaust pipe to the exhaust manifold with the 2 compression springs and 2 bolts. Bolts: 46 ft. lbs. (62 Nm).
     
    All electrical wires and vacuum hoses that were disconnected for removal of the exhaust manifold.
     
    Negative battery cable
     

  4.  

1ZZ-FE Engines
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Drive belt and alternator
     
    Air intake duct
     
    Accelerator cable
     
    Exhaust pipe from the manifold
     
    Exhaust manifold support bracket
     
    Heat insulator from the dash panel
     
    Upper heat insulator
     
    Exhaust manifold and gasket
     
    If necessary, the lower heat insulator from the exhaust manifold.

    Click image to see an enlarged view

    Fig. Exhaust manifold mounting nut locations-1.8L (1ZZ-FE) engine

     

  6.  

To install:

  1. Install or connect the following:

    Lower heat insulator on the exhaust manifold. Bolts: 108 inch lbs. (12 Nm).
     
    Exhaust manifold using a new gasket. Nuts, tightened several passes: 27 ft. lbs. (37 Nm).
     
    Upper heat insulator. Bolts: 108 inch lbs. (12 Nm).
     
    Heat insulator on the dash panel
     
    Exhaust manifold support bracket. Bolts in an alternating pattern: 37 ft. lbs. (49 Nm).
     
    Front exhaust pipe to the manifold. Bolts: 46 ft. lbs. (62 Nm).
     
    Oxygen sensor, using new gasket and nuts. Nuts: 14 ft. lbs. (20 Nm).
     
    Accelerator cable and air intake duct
     
    Alternator and drive belt
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Drive belt and alternator
     
    Air intake duct
     
    Accelerator cable
     
    Exhaust pipe from the manifold
     
    Exhaust manifold support bracket
     
    Heat insulator from the dash panel
     
    Upper heat insulator
     
    Exhaust manifold and gasket
     
    If necessary, the lower heat insulator from the exhaust manifold.

    Click image to see an enlarged view

    Fig. Exhaust manifold mounting nut locations-1.8L (1ZZ-FE) engine

     

  6.  

To install:

  1. Install or connect the following:

    Lower heat insulator on the exhaust manifold. Bolts: 108 inch lbs. (12 Nm).
     
    Exhaust manifold using a new gasket. Nuts, tightened several passes: 27 ft. lbs. (37 Nm).
     
    Upper heat insulator. Bolts: 108 inch lbs. (12 Nm).
     
    Heat insulator on the dash panel
     
    Exhaust manifold support bracket. Bolts in an alternating pattern: 37 ft. lbs. (49 Nm).
     
    Front exhaust pipe to the manifold. Bolts: 46 ft. lbs. (62 Nm).
     
    Oxygen sensor, using new gasket and nuts. Nuts: 14 ft. lbs. (20 Nm).
     
    Accelerator cable and air intake duct
     
    Alternator and drive belt
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

2zz-Ge And 2zz-FE Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Drive belt and alternator
     
    Air intake duct
     
    Accelerator cable
     
    Exhaust pipe from the manifold
     
    Exhaust manifold support bracket
     
    Heat insulator from the dash panel.
     
    Upper heat insulator
     
    Exhaust manifold and gasket
     
    If necessary, the lower heat insulator from the exhaust manifold.
     

  6.  

To install:

  1. Install or connect the following:

    Lower heat insulator on the exhaust manifold. Bolts: 15 ft. lbs. (20 Nm).
     
    Exhaust manifold using a new gasket. Nuts, tightened several passes: 37 ft. lbs. (50 Nm).
     
    Upper heat insulator. Bolts: 15 ft. lbs. (20 Nm).
     
    Heat insulator on the dash panel.
     
    Exhaust manifold support bracket. Bolts: 37 ft. lbs. (49 Nm).
     
    Front exhaust pipe to the manifold. Bolts: 46 ft. lbs. (62 Nm).
     
    Oxygen sensor, using new gasket and nuts. Nuts: 14 ft. lbs. (20 Nm).
     
    Accelerator cable and air intake duct.
     
    Alternator and drive belt.
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

2ZZ-GE Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Drive belt and alternator
     
    Air intake duct
     
    Accelerator cable
     
    Exhaust pipe from the manifold
     
    Exhaust manifold support bracket
     
    Heat insulator from the dash panel.
     
    Upper heat insulator
     
    Exhaust manifold and gasket
     
    If necessary, the lower heat insulator from the exhaust manifold.
     

  6.  

To install:

  1. Install or connect the following:

    Lower heat insulator on the exhaust manifold. Bolts: 15 ft. lbs. (20 Nm).
     
    Exhaust manifold using a new gasket. Nuts, tightened several passes: 37 ft. lbs. (50 Nm).
     
    Upper heat insulator. Bolts: 15 ft. lbs. (20 Nm).
     
    Heat insulator on the dash panel.
     
    Exhaust manifold support bracket. Bolts: 37 ft. lbs. (49 Nm).
     
    Front exhaust pipe to the manifold. Bolts: 46 ft. lbs. (62 Nm).
     
    Oxygen sensor, using new gasket and nuts. Nuts: 14 ft. lbs. (20 Nm).
     
    Accelerator cable and air intake duct.
     
    Alternator and drive belt.
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

5S-FE Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding
     
    Bolts holding the front exhaust pipe to the mounting bracket
     
    Front exhaust pipe from the manifold
     
    Main oxygen sensor connector and the sub oxygen sensor connector
     
    Left-hand exhaust manifold stay
     
    Upper manifold heat insulator
     
    Right-hand exhaust manifold stay
     
    Exhaust manifold, and the 3-way catalytic converter assembly
     
    Oxygen sensor and gasket from the exhaust manifold
     
    Sub oxygen sensor from the 3-way catalytic converter
     
    Lower heat insulator from the exhaust manifold
     
    3-way catalytic converter heat insulators
     
    3-way Catalytic Converter (TWC), gasket, retainer and cushion from the exhaust manifold
     

  4.  

To install:

  1. Place the cushion, retainer, and a new gasket on the TWC and reinstall it to the exhaust manifold with the bolts and the nuts. Bolts and nuts: 22 ft. lbs. (30 Nm).
  2.  
  3. Install or connect the following:

    Lower manifold heat insulator and TWC heat insulators with the bolts.
     
    Main oxygen sensor to the exhaust manifold with a new gasket and new nuts. Nuts: 14 ft. lbs. (19 Nm).
     
    Sub oxygen sensor to the front TWC and tighten to 33 ft. lbs. (45 Nm).
     
    Exhaust manifold, using new gasket and front TWC assembly to the engine with the nuts. Nuts, tighten uniformly in several passes: 36 ft. lbs. (49 Nm).
     
    Right-hand exhaust manifold stay. Bolts and nuts: 31 ft. lbs. (42 Nm).
     
    Upper heat insulator
     
    Left-hand exhaust manifold stay. Bolt: 29 ft. lbs. (39 Nm). Nut: 31 ft. lbs. (42 Nm).
     
    Main and the sub oxygen sensors connectors.
     
    Front exhaust pipe with a new gasket to the TWC. Nuts: 46 ft. lbs. (62 Nm).
     
    Front exhaust pipe to the exhaust pipe bracket. Bolts: 14 ft. lbs. (19 Nm).
     
    Negative battery cable
     

  4.  

7A-FE Engine
  1. Disconnect the negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding.
  2.  


CAUTION
Work must NOT be started until 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 and safely support the vehicle.
  2.  
  3. Working from under the vehicle, remove the bolts holding the front exhaust pipe to the mounting bracket.
  4.  
  5. Using a 14mm deep socket wrench, remove the nuts and the gasket and disconnect the front exhaust pipe from the manifold.
  6.  
  7. Remove the main oxygen sensor connector.
  8.  
  9. Remove the bolts and extract upper heat insulator.
  10.  



Click image to see an enlarged view

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



Click image to see an enlarged view

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



Click image to see an enlarged view

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



Click image to see an enlarged view

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



Click image to see an enlarged view

Fig. ...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.  

 
label.common.footer.alt.autozoneLogo