Exhaust Manifold Installation

Engine Hybrid System. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
2Tr-Fbe Intake Exhaust. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. INSTALL EXHAUST MANIFOLD

  2. INSTALL MANIFOLD STAY

  3. INSTALL FRONT EXHAUST PIPE ASSEMBLY

  4. INSTALL AIR SWITCHING VALVE ASSEMBLY

  5. INSPECT FOR EXHAUST GAS LEAK

  6. INSTALL FRONT FENDER SEAL

  7. INSTALL FRONT UPPER FENDER APRON SEAL

Exhaust Manifold -- Installation



1. INSTALL EXHAUST MANIFOLD
  1. Install a new gasket.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fbe Intake Exhaust.Intake System.Exhaust Manifold  Installation
  1. Install the exhaust manifold with 8 new nuts, and tighten the nuts in the order shown in the illustration.

    Torque:
    36 N*m{367 kgf*cm, 27 ft.*lbf}


2. INSTALL MANIFOLD STAY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Install the manifold stay with the 3 bolts.

    Torque:
    for bolt A:
    72 N*m{730 kgf*cm, 53 ft.*lbf}
    for bolt B:
    44 N*m{449 kgf*cm, 32 ft.*lbf}
    for bolt C:
    30 N*m{306 kgf*cm, 22 ft.*lbf}
    Text in Illustration
    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
    Bolt A
    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
    Bolt B
    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
    Bolt C


3. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Using a vernier caliper, measure the free length of the compression spring.

    Minimum free length:
    40 mm (1.57 in.)
    If the free length is less than the minimum, replace the compression spring.
  1. Install the front exhaust pipe to the exhaust pipe support.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.2Tr-Fbe Intake Exhaust.Intake System.Exhaust Manifold  Installation
  1. Using a plastic-faced hammer and wooden block, tap on a new gasket until its surface is flush with the exhaust manifold.

    Text in Illustration
    *1
    Gasket
    *2
    Wooden Block
    NOTICE:
    1. Be sure to install the gasket so that it faces the correct direction.
    2. Do not reuse the gasket.
    3. Do not damage the gasket.
    4. When connecting the exhaust pipe, do not push in the gasket with the exhaust pipe.
  1. Connect the front exhaust pipe to the exhaust manifold with the 2 compression springs and 2 bolts. Alternately tighten the bolts in several passes.

    Torque:
    43 N*m{438 kgf*cm, 32 ft.*lbf}
  1. Install a new gasket and connect the front exhaust pipe to the center exhaust pipe with the 2 bolts and 2 nuts.

    Torque:
    48 N*m{489 kgf*cm, 35 ft.*lbf}
  1. Connect the heated oxygen sensor connector and attach the wire harness clamp.

  1. Connect the air fuel ratio sensor connector and attach the wire harness clamp.



4. INSTALL AIR SWITCHING VALVE ASSEMBLY
(HILUX_TGN26 RM00000142U00GX.html)


5. INSPECT FOR EXHAUST GAS LEAK
If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.


6. INSTALL FRONT FENDER SEAL
  1. Install the front fender apron seal with the 5 clips.



7. INSTALL FRONT UPPER FENDER APRON SEAL
  1. Install the front upper fender apron seal with the 5 clips.