how to replace Exhaust Manifold on 1997 toyota tacoma

REMOVAL & INSTALLATION

CAUTION

When working on or around an exhaust manifold, make certain all surfaces are cool to the touch before beginning to work.

5VZ-FE Engine
LEFT SIDE

Fig. Exhaust manifold arrangement5VZ-FE engine

Fig. Removing the bolts securing the crossover pipe to the manifolds5VZ-FE engine

Fig. Exhaust manifold retaining nut locations5VZ-FE engine

1. Disconnect the exhaust crossover pipe from the exhaust manifold.
2. Remove the EGR pipe from the manifold.
3. Remove the heat insulator from the manifold.
4. Unfasten the retainers, then remove the manifold.

To install:

5. Install the exhaust manifold to the engine with a new gasket. Tighten the nuts to 30 ft. lbs. (40 Nm).
6. Install the heat insulator, tighten the nuts down to 71 inch lbs. (8 Nm).
7. 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).
8. Attach the crossover pipe to the exhaust manifold, tighten the nuts to 33 ft. lbs. (45 Nm).

RIGHT SIDE

1. Disconnect the exhaust crossover pipe from the exhaust manifold.
2. Remove the exhaust manifold heat insulator.
3. Unfasten the six nuts securing the manifold, then remove the manifold from the engine.

To install:

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

2RZ-FE and 3RZ-FE Engines

Fig. The exhaust pipe must be disconnected from the manifold and its mounting bracket2RZ-FE and 3RZ-FE engines

Fig. Remove the nuts indicated to remove the exhaust manifold2RZ-FE and 3RZ-FE engines

1. Raise and safely support the vehicle.
2. Disconnect the front exhaust pipe from the manifold and mounting bracket.
3. Lower the vehicle.
4. Remove the heat insulator.
5. Remove the exhaust manifold and gasket.

To install:

6. Install the exhaust manifold and gasket to the engine; tighten the nuts to 36 ft. lbs. (49 Nm).
7. Attach the heat insulator, tighten the bolts and nuts to 48 inch lbs. (5 Nm).
8. Raise and support the vehicle.
9. 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).
10. Attach the support bracket, tighten to 29 ft. lbs. (39 Nm).
11. Attach the clamp and tighten to 14 ft. lbs. (19 Nm).
12. Lower the vehicle.
13. Start the engine and check for exhaust leaks.

1FZ-FE Engine

Fig. An extension can be useful for reaching the manifold retaining nuts1FZ-FE engine

Fig. Be sure to use new gaskets when attaching the front header pipe to the catalyst1FZ-FE engine

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

To install:

10. 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).
11. Install the exhaust manifold heat insulators; tighten down to 14 ft. lbs. (19 Nm).
12. Attach the header pipe to the exhaust manifold using new gaskets, tighten the nuts to 46 ft. lbs. (63 Nm).
13. Install the support bracket, and then tighten to 17 ft. lbs. (24 Nm).
14. Attach the clamp, tighten to 14 ft. lbs. (19 Nm).
15. Connect the header pipe to the catalyst using a new gasket to prevent leaks. Tighten to 34 ft. lbs. (46 Nm).
16. Attach the oxygen sensor wire.
17. Connect the negative battery cable.
18. Start the engine and check for exhaust leaks.

2UZ-FE Engine

Fig. Exhaust manifold arrangement and gasket markings2UZ-FE engine

The gaskets between the manifold and head and between the manifold and front exhaust pipe are not reusable. Toyota also specifies that the nuts be replaced with new service parts.

1. Disconnect the negative battery cable.
2. Apply penetrating oil to the nuts and bolts, as required.
3. Remove the nuts from the front pipe that connects the manifold to the three-way catalytic converter
4. Detach the oxygen sensor electrical connector.
5. Remove the small bolts that hold the heat insulator to the manifold.
6. Remove the eight nuts and separate the manifold from the cylinder head. Discard the gasket.

To install:

7. Installation is the reverse of the removal process. Examine the replacement exhaust manifold-to-head gasket. Original equipment Toyota gaskets should have white paint marks on them. The white painted marks should face the manifold side. Use care to install the gasket in the correct direction.
8. Using a new gasket, install the manifold using care to align the studs with the front pipe. A new gasket between the manifold outlet and the front pipe is also required. Use new service replacement nuts. Uniformly tighten the nuts to 32 ft. lbs. (44 Nm).
9. Install the heat insulator and tighten the four bolts to just 66 inch lbs. (7.5 Nm).
10. Tighten the manifold-to-front pipe nuts to 46 ft. lbs. (62 Nm).
11. Connect the negative battery cable, start the engine and verify no exhaust leaks.

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