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Exhaust Pipe: Installation

CAUTION: Perform the procedures below with at least 2 people.
  1. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY 
    1. Install the bracket with the 2 bolts.

      Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 

      Fig 1: Locating Bracket Bolts
      G04943772Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL TAILPIPE RH 
    1. Connect the 3 exhaust pipe supports to install the tailpipe.
      2. Fig 2: Locating Tailpipe Correct And Incorrect Position
      G04943774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL TAILPIPE LH 
    1. Connect the 3 exhaust pipe supports to install the tailpipe.
  4. INSTALL FRONT EXHAUST PIPE ASSEMBLY 
    1. Install 2 new gaskets to the exhaust manifold LH and RH.
      NOTE: Do not reuse the 2 removed gaskets.
      Fig 3: Locating Exhaust Manifold Gaskets
      G04943775Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install 2 new gaskets to the exhaust pipe rear ends.
      NOTE: Do not reuse the 2 removed gaskets.
      Fig 4: Locating Exhaust Pipe Rear Ends To Gaskets
      G04943776Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the front exhaust pipe to the exhaust manifold LH and RH with the 4 bolts and 4 new nuts.

      Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf) 

      NOTE: Do not reuse the 4 removed nuts.
    4. Install the front exhaust pipe's tailpipe LH and RH side with the 4 bolts.

      Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf) 

      Fig 5: Identifying Front Exhaust Pipe's Tailpipe
      G04943777Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL FRONT FLOOR CENTER BRACE 
    1. Install the brace with the 4 bolts.

      Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf) 

      Fig 6: Locating Brace With Bolts
      G04943778Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. CONNECT HEATED OXYGEN SENSOR (for Sensor 2) 
    NOTE: Do not strike the metal part of the sensor.
    1. Pre-rotate the sensor 4 times counterclockwise, and then install the sensor to the exhaust pipe by hand.
      Fig 7: Rotating Sensor
      G04943779Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, tighten the 2 sensors.

      SST 09224-00010 

      Torque: with SST 

      40 N*m (408 kgf*cm, 30 ft.*lbf) 

      without SST 

      44 N*m (449 kgf*cm, 32 ft.*lbf) 

      NOTE:
      • Make sure SST and the wrench are connected in a straight line.
      • Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).
        Fig 8: Identifying Fulcrum Length
        G04943780Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the 2 grommets to the floor panel.
      Fig 9: Locating Grommets To Floor Panel
      G04943770Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSPECT FOR EXHAUST GAS LEAK 
    1. If gas is leaking, tighten the areas necessary to stop the leak. Replace the damaged parts as necessary.
  8. INSTALL FRONT FLOOR COVER RH 
    1. Install the cover with the 3 clips, 3 screws and 4 grommets.
      2. Fig 10: Locating Front Floor Cover Clips, Cover And Screw
      G04943768Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL FRONT FLOOR COVER LH 
    1. Install the cover with the 3 clips, 3 screws and 4 grommets.
  10. INSTALL REAR FLOOR SIDE MEMBER COVER RH 
    1. Install the cover with the clip, nut and 5 screws.
      2. Fig 11: Locating Cover Clip, Nut Screws
      G05854584Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE REAR FLOOR SIDE MEMBER COVER LH 
    1. Install the cover with the clip, nut and 5 screws.
  12. INSTALL NO. 5 ROCKER PANEL MOULDING PROTECTOR 
    1. Install the protector with the 2 clips and screw.
  13. INSTALL NO. 6 ROCKER PANEL MOULDING PROTECTOR 
    1. Install the protector with the 2 clips and screw.
  14. INSTALL NO. 1 DIFFERENTIAL SUPPORT PROTECTOR  (See INSTALLATION )
  15. INSTALL NO. 2 DIFFERENTIAL SUPPORT PROTECTOR  (See INSTALLATION )
  16. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  17. INSTALL COWL TOP VENTILATOR LOUVER RH  (See INSTALLATION )
  18. PERFORM INITIALIZATION 
    1. Perform initialization (see INITIALIZATION ).
      NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
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