Toyota Pick-ups/Land Cruiser/4Runner 1989-1996

Exhaust Manifold

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REMOVAL & INSTALLATION




CAUTION
When working on or around a manifold, make ceratin all surfaces are cool to the touch before beginning to work.

22R, 22R-E, and 3VZ-E Engines

See Figures 1, 2 and 3

  1. Remove the three exhaust pipe flange bolts and disconnect the exhaust pipe from the manifold.
  2.  



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Fig. Fig. 1: Exploded view of the exhaust manifold assembly found on 22R engines with Federal emissions



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Fig. Fig. 2: Exhaust manifold found on 22R engines with Canadian emissions



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Fig. Fig. 3: Exploded view of the 22R California emission exhaust manifold assembly

  1. Tag and disconnect the spark plug leads. Position the spark plug wires out of the way. It is best to tie them so they don't get in your way.
  2.  
  3. Remove the air cleaner tube from the heat stove on carbureted engines, and remove the outer part of the heat stove.
  4.  
  5. Use a 14 mm wrench to remove the manifold retaining nuts.
  6.  
  7. Remove the manifold(s), complete with air injection tubes and the inner portion of the heat stove.
  8.  
  9. For 22R engines, separate the inner portion of the heat stove from the manifold.
  10.  

To install:
  1. Always use a new gasket. Install any disassembled parts onto the manifold and place it in position.
  2.  
  3. Install the nuts and bolts, tightening them to 30 ft. lbs. (40 Nm).
  4.  
  5. Install the air cleaner and spark plug leads. Connect the air intake tube(s).
  6.  
  7. Connect the exhaust pipe to the manifold, tightening the bolts to 30 ft. lbs. (40 Nm)
  8.  

5VZ-FE Engine

See Figures 4 and 5

LEFT SIDE



  1. Disconnect the exhaust crossover pipe from the exhaust manifold.
  2.  
  3. Remove the EGR pipe from the manifold.
  4.  
  5. Remove the heat insulator from the manifold.
  6.  
  7. Remove the manifold.
  8.  

To install:
  1. Install the exhaust manifold to the engine with a new gasket. Tighten the nuts to 30 ft. lbs. (40 Nm).
  2.  
  3. Install the heat insulator, tighten the nuts down to 71 inch lbs. (8 Nm).
  4.  
  5. Connect the EGR pipe to the manifold. Tighten the nuts to 14 ft. lbs. (18 Nm). Tighten the clamp nuts to 71 inch lbs. (8 Nm).
  6.  
  7. Attach the crossover pipe to the exhaust manifold, tighten the nuts to 33 ft. lbs. (45 Nm).
  8.  



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Fig. Fig. 4: Remove the bolts securing the crossover pipe to the manifold(s)



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Fig. Fig. 5: Exhaust manifold retaining nut locations

RIGHT SIDE

  1. Disconnect the exhaust crossover pipe from the exhaust manifold.
  2.  
  3. Remove the exhaust manifold heat insulator.
  4.  
  5. Unfasten the six nuts securing the manifold from the engine.
  6.  

To install:
  1. Install the exhaust manifold with the new gasket, tighten the six nuts to 30 ft. lbs. (40 Nm).
  2.  
  3. Attach the heat insulator, tighten the nuts to 71 inch lbs. (8 Nm).
  4.  
  5. Connect the crossover pipe with a new gasket, to the exhaust manifold. Tighten the nuts to 33 ft. lbs. (45 Nm).
  6.  

2RZ-FE and 3RZ-FE Engines

See Figures 6 and 7

  1. Raise and safely support the vehicle.
  2.  
  3. Disconnect the front exhaust pipe from the manifold and mounting bracket.
  4.  



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Fig. Fig. 6: The exhaust pipe must be disconnected from the manifold and its mounting bracket

  1. Lower the vehicle.
  2.  
  3. Remove the heat insulator.
  4.  
  5. Remove the exhaust manifold and gasket.
  6.  



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Fig. Fig. 7: Remove the nuts indicated to remove the exhaust manifold

To install:
  1. Install the exhaust manifold and gasket to the engine, tighten the nuts to 36 ft. lbs. (49 Nm).
  2.  
  3. Attach the heat insulator, tighten the bolts and nuts to 48 inch lbs. (5 Nm).
  4.  
  5. Raise and support the vehicle.
  6.  
  7. Install the front exhaust pipe to the manifold with new gaskets. Apply a gasket to the front pipe, install the nuts and tighten to 46 ft. lbs. (62 Nm).
  8.  
  9. Attach the support bracket, tighten to 29 ft. lbs. (39 Nm).
  10.  
  11. Attach the clamp and tighten to 14 ft. lbs. (19 Nm).
  12.  
  13. Lower the vehicle.
  14.  
  15. Start the engine and check for exhaust leaks.
  16.  

1FZ-FE Engine

See Figures 8 and 9

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Working from underneath the vehicle, disconnect the oxygen sensor wire.
  6.  
  7. Remove the nuts and bolts holding the front header pipe to the catalytic converter.
  8.  
  9. Loosen the pipe clamp.
  10.  
  11. Remove the pipe bracket.
  12.  
  13. Unbolt the front header pipe and remove the gasket.
  14.  
  15. Lower the vehicle, remove the exhaust manifold heat shield insulators.
  16.  
  17. Remove the nuts from the exhaust manifolds, then the gaskets.
  18.  

To install:
  1. Install the exhaust manifolds to the engine with new gaskets. Uniformly tighten the nuts in several passes. Tighten the nuts to 29 ft. lbs. (39 Nm).
  2.  



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Fig. Fig. 8: An extension can be useful for reaching the manifold retaining nuts

  1. Install the exhaust manifold heat insulators, tighten down to 14 ft. lbs. (19 Nm).
  2.  
  3. Attach the header pipe to the exhaust manifold using new gaskets, tighten the nuts to 46 ft. lbs. (63 Nm).
  4.  
  5. Install the support bracket, then tighten to 17 ft. lbs. (24 Nm).
  6.  
  7. Attach the clamp, tighten to 14 ft. lbs. (19 Nm).
  8.  
  9. Connect the header pipe to the catalyst using a new gasket to prevent leaks. Tighten to 34 ft. lbs. (46 Nm).
  10.  



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Fig. Fig. 9: Be sure to use new gaskets when attaching the front header pipe to the catalyst

  1. Attach the oxygen sensor wire.
  2.  
  3. Connect the negative battery cable.
  4.  
  5. Start the engine and check for exhaust leaks.
  6.  

 
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