Toyota Tercel 1984-1994 Repair Guide

Exhaust Manifold

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REMOVAL & INSTALLATION



See Figures 1, 2 and 3

3A and 3A-C Engines

Please refer to the Combination Manifold procedure in this section.

3E and 3E-E Engines

CAUTION
On models equipped with a Supplemental Restraint System (SRS) or "air bag,'' work must NOT be started until at least 90 seconds have passed from the time that both the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove any components necessary to gain access to the exhaust manifold retaining bolts.
  4.  



Click image to see an enlarged view

Fig. Fig. 1: Removing the external heat insulator

  1. Disconnect the exhaust manifold bolts at the exhaust pipe. Disconnect the oxygen sensor electrical wire. It may be necessary to raise and support the vehicle safely before removing these bolts.
  2.  
  3. Remove the three external heat insulator attaching bolts.
  4.  
  5. Remove the six exhaust manifold retaining nuts. Remove the exhaust manifold, internal heat insulator and gaskets from the vehicle.
  6.  
  7. Using a precision straight edge and thickness gauge, check the surface contacting the cylinder head for warpage. It should not exceed 0.0118 in. (0.30mm). If the warpage exceeds these specifications, replace the manifold.
  8.  

To install:
  1. Install a new exhaust manifold gasket, the E mark on the gasket must face outward.
  2.  



Click image to see an enlarged view

Fig. Fig. 2: Removing the internal heat insulator and the exhaust manifold



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Fig. Fig. 3: On 3E and 3E-E engines, the exhaust manifold gasket must be installed with the E mark facing outward

  1. Assemble the internal heat insulator and exhaust manifold onto the engine. Tighten the nuts, refer to the torque specifications chart in this section.
  2.  
  3. Install the external heat insulator and tighten the bolts until snug.
  4.  
  5. Connect the exhaust pipe to the manifold.
  6.  
  7. Install or connect any other components removed earlier.
  8.  
  9. Start the engine and check for exhaust leaks. Road test for proper operation.
  10.  

 
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