Toyota Prius: Exhaust Manifold

• Removal
• Installation

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 removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed	Link
Replacement of air fuel ratio sensor Gas leak from exhaust system is repaired	Inspection after repair	Poor idle, etc. Engine start function, etc.

Procedure		Part Name Code
1	WINDSHIELD WIPER MOTOR AND LINK	-	-	-	-
2	WATER GUARD PLATE	55734D	-	-	-
3	OUTER COWL TOP PANEL SUB-ASSEMBLY	55701J	-	-	-

Procedure		Part Name Code
4	AIR FUEL RATIO SENSOR	89467B		-	-
5	FRONT FLOOR COVER LH	58166A		-	-
6	FRONT FLOOR COVER RH	58165C		-	-
7	FRONT FLOOR CENTER BRACE	57533B	-	-	-
8	FRONT EXHAUST PIPE ASSEMBLY	17410		-	-
9	FRONT NO. 1 FLOOR HEAT INSULATOR	58151	-	-	-
10	NO. 1 ENGINE UNDER COVER ASSEMBLY	51410	-	-	-
11	WIRING HARNESS CLAMP BRACKET	-		-	-
12	NO. 1 EXHAUST MANIFOLD HEAT INSULATOR	17617		-	-
13	MANIFOLD STAY	17118		-	-
14	EXHAUST MANIFOLD	17141		-	-
15	NO. 2 EXHAUST MANIFOLD HEAT INSULATOR	17168	-	-	-

●

Non-reusable part

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PROCEDURE

1. REMOVE WINDSHIELD WIPER MOTOR AND LINK

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2. REMOVE WATER GUARD PLATE

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3. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY

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4. REMOVE AIR FUEL RATIO SENSOR

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5. REMOVE FRONT FLOOR COVER LH

(1) Remove the bolt, 2 nuts, and 2 clips.

(2) Turn the clip and remove the front floor cover LH from the Toyota Prius vehicle body.

NOTICE:

If the clip is not turned when the front floor cover LH is removed, the front floor cover LH or stud bolt may be damaged.

HINT:

Do not remove the clip from the front floor cover LH.

6. REMOVE FRONT FLOOR COVER RH

(1) Remove the bolt, 2 nuts, and 2 clips.

(2) Turn the clip and remove the front floor cover RH from the Toyota Prius vehicle body.

NOTICE:

If the clip is not turned when the front floor cover RH is removed, the front floor cover RH or stud bolt may be damaged.

HINT:

Do not remove the clip from the front floor cover RH.

7. REMOVE FRONT FLOOR CENTER BRACE

8. REMOVE FRONT EXHAUST PIPE ASSEMBLY

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

9. REMOVE FRONT NO. 1 FLOOR HEAT INSULATOR

10. REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY

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11. REMOVE WIRING HARNESS CLAMP BRACKET

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

12. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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

13. REMOVE MANIFOLD STAY

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

14. REMOVE EXHAUST MANIFOLD

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

15. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

Installation

INSTALLATION

CAUTION / NOTICE / HINT

Procedure		Part Name Code
1	NO. 2 EXHAUST MANIFOLD HEAT INSULATOR	17168	-	-	-
2	EXHAUST MANIFOLD	17141		-	-
3	MANIFOLD STAY	17118		-	-
4	NO. 1 EXHAUST MANIFOLD HEAT INSULATOR	17617	-	-	-
5	WIRING HARNESS CLAMP BRACKET	-	-	-	-
6	FRONT NO. 1 FLOOR HEAT INSULATOR	58151	-	-	-
7	FRONT EXHAUST PIPE ASSEMBLY	17410		-	-
8	FRONT FLOOR CENTER BRACE	57533B	-	-	-
9	FRONT FLOOR COVER RH	58165C	-	-	-
10	FRONT FLOOR COVER LH	58166A	-	-	-
11	SENSOR, AIR FUEL RATIO	89467B		-	-
12	INSPECT FOR EXHAUST GAS LEAK	-	-	-
13	NO. 1 ENGINE UNDER COVER ASSEMBLY	51410	-	-	-

	N*m (kgf*cm, ft.*lbf): Specified torque	●	Non-reusable part
*	For use with SST	-	-

Procedure		Part Name Code
14	OUTER COWL TOP PANEL SUB-ASSEMBLY	55701J	-	-	-
15	WATER GUARD PLATE	55734D	-	-	-
16	WINDSHIELD WIPER MOTOR AND LINK	-	-	-	-

Tightening torque for "Major areas involving basic Toyota Prius vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)

N*m (kgf*cm, ft.*lbf): Specified torque

PROCEDURE

1. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

Torque:

12 N·m {122 kgf·cm, 9 ft·lbf}

2. INSTALL EXHAUST MANIFOLD

(1) Install a new exhaust manifold to head gasket and EGR cooler gasket to the cylinder head sub-assembly.

(2) Temporarily install the exhaust manifold to the cylinder head sub-assembly with 7 new nuts.

(3) Using a 12 mm deep socket wrench, tighten the 7 nuts in the order shown in the illustration.

Torque:

26 N·m {265 kgf·cm, 19 ft·lbf}

3. INSTALL MANIFOLD STAY

(1) Tighten the 3 bolts in the order shown in the illustration.

Torque:

43 N·m {438 kgf·cm, 32 ft·lbf}

4. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

Torque:

12 N·m {122 kgf·cm, 9 ft·lbf}

5. INSTALL WIRING HARNESS CLAMP BRACKET

Torque:

39 N·m {398 kgf·cm, 29 ft·lbf}

6. INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR

Torque:

5.0 N·m {51 kgf·cm, 44 in·lbf}

7. INSTALL FRONT EXHAUST PIPE ASSEMBLY

*1	Exhaust Manifold or Front Exhaust Pipe Assembly	*2	Gasket
*a	Wooden Block	*b	Plastic Hammer

(1) Using a vernier caliper, measure the free length of the compression springs.

Standard Length (Front)	43 mm (1.69 in.)
Standard Length (Rear)	40 mm (1.57 in.)
Minimum Free Length (Front)	41.5 mm (1.63 in.)
Minimum Free Length (Rear)	38.5 mm (1.52 in.)

If the free length is less than the minimum, replace the compression spring.

(2) temporarily install 2 new gaskets to the exhaust manifold and front exhaust pipe assembly.

(3) Using a plastic hammer and wooden block, tap in each gasket until its surface is flush with the exhaust manifold and front exhaust pipe assembly.

*1	Exhaust Manifold	*2	Front Exhaust Pipe Assembly
*3	Tail Exhaust Pipe Assembly	*4	Gasket
*a	Space between Flanges: 8.5 mm (0.335in.)	*b	Space between Flanges: 6.5 mm (0.256in.)

(1) Connect the front exhaust pipe assembly to the 2 exhaust pipe supports.

(2) Install the front exhaust pipe assembly to the exhaust manifold with the 2 compression springs and 2 bolts.

Torque:

43 N·m {438 kgf·cm, 32 ft·lbf}

(3) After installation, check that the space between the flanges of the exhaust manifold and front exhaust pipe assembly is consistent front-to-rear and left-to-right.

(4) Install the front exhaust pipe assembly to the tail exhaust pipe assembly with the 2 compression springs and 2 bolts.

Torque:

43 N·m {438 kgf·cm, 32 ft·lbf}

(5) After installation, check that the space between the flanges of the front exhaust pipe assembly and tail exhaust pipe assembly is consistent front-to-rear and left-to-right.

(6) Engage the wire harness clamp.

(7) Connect the heated oxygen sensor connector.

8. INSTALL FRONT FLOOR CENTER BRACE

Torque:

27 N·m {275 kgf·cm, 20 ft·lbf}

9. INSTALL FRONT FLOOR COVER RH

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

10. INSTALL FRONT FLOOR COVER LH

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

11. INSTALL AIR FUEL RATIO SENSOR

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12. INSPECT FOR EXHAUST GAS LEAK

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13. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

Torque:

12 N·m {122 kgf·cm, 9 ft·lbf}

14. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

Torque:

Bolt :

12 N·m {122 kgf·cm, 9 ft·lbf}

Nut :

50 N·m {510 kgf·cm, 37 ft·lbf}

15. INSTALL WATER GUARD PLATE

16. INSTALL WINDSHIELD WIPER MOTOR AND LINK

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