Toyota Cressida and Van 1983-1990

Exhaust Manifold

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REMOVAL & INSTALLATION



5M-GE Engine


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Fig. Fig. 1 When installing the intake manifold, use a torque wrench and tighten to specifications-5M-GE engine

  1. Disconnect the negative battery cable. Raise the vehicle and support safely. Remove the right-hand gravel shield from underneath the vehicle.
  2.  
  3. Remove the throttle body.
  4.  
  5. Remove the exhaust pipe support stay. Unbolt the exhaust pipe from the exhaust manifold flange.
  6.  
  7. Disconnect the oxygen sensor connector.
  8.  
  9. Remove the manifold retaining nuts. Remove the exhaust manifold from the vehicle.
  10.  

To install:

  1. Install the exhaust manifold gasket along with the exhaust manifold. Install the exhaust manifold retaining bolts and torque to specification.
  2.  
  3. Reconnect the oxygen sensor connector.
  4.  
  5. Install the exhaust pipe support stay. Install the exhaust pipe to the exhaust manifold flange.
  6.  
  7. Install the throttle body.
  8.  
  9. Install the right-hand gravel shield underneath the vehicle. Lower the vehicle and install the negative battery cable.
  10.  
  11. Start the engine check for any exhaust leaks at the manifold.
  12.  

7M-GE Engine


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Fig. Fig. 2 The heat shield over the exhaust manifold must be removed first-7M-GE engine

  1. Disconnect the negative battery cable. Remove the exhaust manifold heat insulator shield assembly, if equipped.
  2.  
  3. Remove the necessary components in order to gain access to the exhaust manifold retaining bolts.
  4.  
  5. Disconnect the exhaust manifold bolts 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. Install the exhaust manifold gasket along with the exhaust manifold. Install the exhaust manifold retaining bolts and torque to specification.
  2.  
  3. Install all the components that had been removed in order to gain access to the exhaust manifold.
  4.  
  5. Install the exhaust manifold heat shield and negative battery cable.
  6.  
  7. Start the engine check for any exhaust leaks at the manifold.
  8.  

3Y-EC and 4Y-EC Engines


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Fig. Fig. 3 View of the intake and exhaust manifolds-3Y-EC and 4Y-EC engines



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Fig. Fig. 4 Before removing the manifolds, disconnect the accelerator cable and bracket from the throttle body



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Fig. Fig. 5 Remove the air intake chamber and throttle body as an assembly-3Y-EC and 4Y-EC engines



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Fig. Fig. 6 Remove the bracket on top of the intake manifold-3Y-EC and 4Y-EC engines



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Fig. Fig. 7 Spray the intake manifold nuts with penetrating oil to ease nut removal



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Fig. Fig. 8 Remove the exhaust manifold down pipe mounting nuts



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Fig. Fig. 9 Unbolt the manifold stay bracket from the engine-3Y-EC and 4Y-EC engines



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Fig. Fig. 10 1. Intake manifold



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Fig. Fig. 11 Unbolt the exhaust manifold heat shields



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Fig. Fig. 12 First remove the small shield from on top of the large heat shield ...



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Fig. Fig. 13 ... then remove the large exhaust manifold heat shield-3Y-EC and 4Y-EC engines



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Fig. Fig. 14 Separate the exhaust manifold from the engine ...



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Fig. Fig. 15 ... then remove and discard the gasket



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Fig. Fig. 16 Dont forget to remove and discard the old exhaust manifold-to-head pipe gasket

  1. Relieve the fuel pressure from the fuel injection system. Disconnect the negative battery cable and remove the right-hand seat and engine service hole cover.
  2.  
  3. Drain the engine coolant into a suitable container.
  4.  
  5. Remove the air cleaner to the throttle body hose.
  6.  
  7. Remove the accelerator cable with the bracket from the throttle body.
  8.  
  9. Disconnect the air valve, throttle position sensor connector and the oxygen sensor wiring.
  10.  
  11. Disconnect the PCV hose from the air intake chamber, the water bypass hoses from the throttle body, the booster vacuum hose and the charcoal canister hose, then label and disconnect the emission control cable.
  12.  
  13. Remove the EGR tube union nut from the exhaust manifold, the EGR valve from the air intake chamber.
  14.  
  15. Disconnect the cold start injector tube, water bypass hoses and the pressure regulator hose from the intake manifold.
  16.  
  17. Remove the air intake chamber brackets and the air intake chamber with the air valve from the intake manifold.
  18.  
  19. Remove the wire clamp bolt from the fuel injector rail, then, the fuel injector rail from the fuel injectors.
  20.  
  21. Remove the exhaust manifold to intake manifold bracket, the exhaust manifold to engine bracket, the fuel inlet and outlet tubes union nut from the fuel rail.
  22.  
  23. Remove the spark plug wires, the spark plugs and the tubes.
  24.  
  25. Remove the retaining nuts, then the intake manifold.
  26.  
  27. Unbolt and remove the exhaust manifold heat shields.
  28.  
  29. Separate the exhaust manifold from the head pipe and discard the gasket.
  30.  
  31. Pull the exhaust manifold off the engine and discard the gasket.
  32.  

To install:

  1. Clean the gasket mounting surfaces.
  2.  
  3. Installation is the reverse order of the removal procedure, except for the following.
  4.  
    1. Install new gaskets.
    2.  
    3. Tighten the manifold to cylinder head nuts to 36 ft. lbs. (49 Nm).
    4.  
    5. Tighten the air intake chamber to intake manifold bolts to 9 ft. lbs.
    6.  
    7. Tighten the throttle body bolts to 9 ft. lbs. (12 Nm).
    8.  
    9. Refill the cooling system. Start the engine and allow it to reach normal operating temperature and check for leaks. Repair as necessary.
    10.  


 
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