Toyota Avalon (XX50): Exhaust Manifold

Components

COMPONENTS

ILLUSTRATION

*1	FRONT FLOOR COVER LH	*2	FRONT FLOOR COVER RH
	N*m (kgf*cm, ft.*lbf): Specified torque	-	-

ILLUSTRATION

*A	Type A	*B	Type B
*1	NO. 1 ENGINE UNDER COVER	*2	FRONT WHEEL OPENING EXTENSION PAD LH
*3	FRONT WHEEL OPENING EXTENSION PAD RH	*4	REAR ENGINE UNDER COVER RH
*5	BODY MOUNTING PLATE	*6	COOL AIR INTAKE DUCT SEAL
	N*m (kgf*cm, ft.*lbf): Specified torque	-	-

ILLUSTRATION

*1	FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)	*2	NO. 1 EXHAUST PIPE SUPPORT BRACKET (for Lower Side)
*3	EXHAUST PIPE SUPPORT	*4	GASKET
	N*m (kgf*cm, ft.*lbf): Specified torque	●	Non-reusable part

ILLUSTRATION

*1	EXHAUST MANIFOLD ASSEMBLY RH (TWC: Front Catalyst)	*2	EXHAUST MANIFOLD ASSEMBLY LH (TWC: Front Catalyst)
*3	NO. 2 EXHAUST MANIFOLD HEAT INSULATOR	*4	NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
*5	EXHAUST MANIFOLD TO HEAD GASKET (for Bank 1)	*6	EXHAUST MANIFOLD TO HEAD GASKET (for Bank 2)
*7	AIR FUEL RATIO SENSOR (for Bank 1)	*8	AIR FUEL RATIO SENSOR (for Bank 2)
*9	NO. 2 MANIFOLD STAY	*10	V-BANK COVER SUB-ASSEMBLY
*11	STUD BOLT	*12	ENGINE OIL LEVEL DIPSTICK
*13	ENGINE OIL LEVEL DIPSTICK GUIDE	*14	ENGINE OIL LEVEL DIPSTICK GUIDE O-RING
	N*m (kgf*cm, ft.*lbf): Specified torque	*	For use with SST
●	Non-reusable part	-	-

Installation

INSTALLATION

PROCEDURE

1. INSTALL STUD BOLT

HINT:

If a stud bolt is deformed or its threads are damaged, replace it.

(a) Using an E8 "TORX" socket wrench, install the 2 stud bolts to the exhaust manifold assembly LH (TWC: Front Catalyst). Torque: 19.5 N·m {199 kgf·cm, 14 ft·lbf}

2. INSTALL EXHAUST MANIFOLD TO HEAD GASKET (for Bank 2)

(a) Install a new exhaust manifold to head gasket (for Bank 2) to the cylinder head sub-assembly.

3. INSTALL EXHAUST MANIFOLD ASSEMBLY LH (TWC: Front Catalyst)

(a) Temporarily install the exhaust manifold assembly LH (TWC: Front Catalyst) with the 4 nuts.

(b) Temporarily install the No. 2 manifold stay to the exhaust manifold assembly LH (TWC: Front Catalyst) and cylinder block sub-assembly with the bolt and nut.

(c) Using a 12 mm deep socket wrench, tighten the 4 nuts in the order shown in the illustration. Torque: 21 N·m {214 kgf·cm, 15 ft·lbf}

(d) Tighten the bolt and nut in the order shown in the illustration.

	Bolt
	Nut

Torque:

Nut :

35 N·m {357 kgf·cm, 26 ft·lbf}

Bolt :

34 N·m {347 kgf·cm, 25 ft·lbf}

4. CONNECT NO. 5 WATER BY-PASS HOSE

(a) Engage the 2 clamps to connect the No. 5 water by-pass hose and No. 6 water by-pass hose to the hose clamp.

5. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

(a) Install the No. 2 exhaust manifold heat insulator to the exhaust manifold assembly LH (TWC: Front Catalyst) with the 3 bolts in the order shown in the illustration. Torque: 8.5 N·m {87 kgf·cm, 75 in·lbf}

6. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

Click here

7. INSTALL AIR FUEL RATIO SENSOR (for Bank 2)

Click here

8. INSTALL COOL AIR INTAKE DUCT SEAL

Click here

9. INSTALL V-BANK COVER SUB-ASSEMBLY

Click here

10. INSTALL EXHAUST MANIFOLD TO HEAD GASKET (for Bank 1)

(a) Install a new exhaust manifold to head gasket (for Bank 1) to the cylinder head sub-assembly RH.

11. INSTALL EXHAUST MANIFOLD ASSEMBLY RH (TWC: Front Catalyst)

(a) Temporarily install the exhaust manifold assembly RH (TWC: Front Catalyst) with the 4 nuts.

(b) Using a 12 mm deep socket wrench, tighten the 4 nuts in the order shown in the illustration. Torque: 21 N·m {214 kgf·cm, 15 ft·lbf}

12. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

(a) Install the No. 1 exhaust manifold heat insulator to the exhaust manifold assembly RH (TWC: Front Catalyst) with the 3 bolts in the order shown in the illustration. Torque: 8.5 N·m {87 kgf·cm, 75 in·lbf}

*a Temporarily Tighten

13. INSTALL AIR FUEL RATIO SENSOR (for Bank 1)

Click here

14. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)

(a) Install 3 new gaskets to the front exhaust pipe assembly (TWC: Rear Catalyst).

(b) Connect the front exhaust pipe assembly (TWC: Rear Catalyst) to the exhaust pipe support.

(c) Install the front exhaust pipe assembly (TWC: Rear Catalyst) with 4 new bolts and 4 new nuts.

Torque:

43 N·m {438 kgf·cm, 32 ft·lbf}

(d) Engage the 2 wire harness clamps.

(e) Connect the 2 heated oxygen sensor connectors.

15. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET (for Lower Side)

Click here

16. INSTALL BODY MOUNTING PLATE

Click here

17. INSTALL FRONT FLOOR COVER LH

Click here

18. INSTALL FRONT FLOOR COVER RH

Click here

19. INSPECT FOR EXHAUST GAS LEAK

Click here

20. INSTALL REAR ENGINE UNDER COVER RH

Click here

21. INSTALL NO. 1 ENGINE UNDER COVER

Click here

22. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH

Click here

23. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH

Click here

Removal

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during exhaust manifold assembly RH (TWC: Front Catalyst) and exhaust manifold assembly LH (TWC: Front Catalyst) removal/installation are shown below.

CAUTION:

• To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.
• To prevent burns, do not touch the engine, exhaust pipe or other high temperature components while the engine is hot.

PROCEDURE

1. REMOVE FRONT FLOOR COVER LH

Click here

2. REMOVE FRONT FLOOR COVER RH

Click here

3. REMOVE BODY MOUNTING PLATE

Click here

4. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET (for Lower Side)

Click here

5. REMOVE FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)

(a) Disconnect the 2 heated oxygen sensor connectors.

(b) Disengage the 2 wire harness clamps.

(c) Remove the 4 bolts, 4 nuts and disconnect the front exhaust pipe assembly (TWC: Rear Catalyst).

(d) Remove the front exhaust pipe assembly (TWC: Rear Catalyst) from the exhaust pipe support.

(e) Remove the 3 gaskets from the front exhaust pipe assembly (TWC: Rear Catalyst).

6. REMOVE AIR FUEL RATIO SENSOR (for Bank 1)

Click here

7. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

(a) Remove the 3 bolts and No. 1 exhaust manifold heat insulator from the exhaust manifold assembly RH (TWC: Front Catalyst).

8. REMOVE EXHAUST MANIFOLD ASSEMBLY RH (TWC: Front Catalyst)

(a) Using a 12 mm deep socket wrench, remove the 4 nuts and exhaust manifold assembly RH (TWC: Front Catalyst) from the cylinder head sub-assembly RH.

9. REMOVE EXHAUST MANIFOLD TO HEAD GASKET (for Bank 1)

(a) Remove the exhaust manifold to head gasket (for Bank 1) from the cylinder head sub-assembly RH.

10. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH

Click here

11. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH

Click here

12. REMOVE NO. 1 ENGINE UNDER COVER

Click here

13. REMOVE REAR ENGINE UNDER COVER RH

Click here

14. REMOVE V-BANK COVER SUB-ASSEMBLY

Click here

15. REMOVE COOL AIR INTAKE DUCT SEAL

Click here

16. REMOVE AIR FUEL RATIO SENSOR (for Bank 2)

Click here

17. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

Click here

18. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

(a) Remove the 3 bolts and No. 2 exhaust manifold heat insulator from the exhaust manifold assembly LH (TWC: Front Catalyst).

19. REMOVE NO. 2 MANIFOLD STAY

(a) Remove the bolt, nut and No. 2 manifold stay from the exhaust manifold assembly LH (TWC: Front Catalyst) and cylinder block sub-assembly.

	Bolt
	Nut

20. DISCONNECT NO. 5 WATER BY-PASS HOSE

(a) Disengage the 2 clamps to disconnect the No. 5 water by-pass hose and No. 6 water by-pass hose from the hose clamp.

21. REMOVE EXHAUST MANIFOLD ASSEMBLY LH (TWC: Front Catalyst)

(a) Using a 12 mm deep socket wrench, remove the 4 nuts and exhaust manifold assembly LH (TWC: Front Catalyst).

22. REMOVE EXHAUST MANIFOLD TO HEAD GASKET (for Bank 2)

(a) Remove the exhaust manifold to head gasket (for Bank 2) from the cylinder head sub-assembly.

23. REMOVE STUD BOLT

HINT:

If a stud bolt is deformed or its threads are damaged, replace it.

(a) Using an E8 "TORX" socket wrench, remove the 2 stud bolts from the exhaust manifold assembly LH (TWC: Front Catalyst).