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Engine Exhaust Assembly (4GR-FSE): Installation

  1. INSTALL TAIL EXHAUST PIPE BAFFLE SUB-ASSEMBLY 
    1. Align the baffle with the protruding part of the tail exhaust pipe assembly as shown in the illustration.
      2. Fig 1: Installs Tail Exhaust Pipe Baffle
      G00437590Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a plastic hammer, uniformly tap the baffle sub-assemblies onto the tail exhaust pipe assembly.
  2. INSTALL EXHAUST PIPE DAMPER 
    1. Install the exhaust pipe damper with the 2 bolts. Torque: 19 Nm (194 kgfcm, 14 ftlbf)
      2. Fig 2: Locating Exhaust Pipe Damper
      G00437588Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL TAIL EXHAUST PIPE ASSEMBLY  
    1. Install the tail exhaust pipe assembly with the 6 exhaust pipe supports.
      2. Fig 3: Locating Tail Exhaust Pipe Assembly
      G00437587Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL FRONT EXHAUST PIPE ASSEMBLY 
    1. Using a vernier caliper, measure the free length of the compression springs. Minimum length: 38.5 mm (1.516 in.). If the free length is less than the minimum, replace the compression spring.
      2. Fig 4: Measuring Compression Spring Free Length
      G00437591Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install a new gasket to the rear end of the front exhaust pipe.
      3. Fig 5: Locating New Gasket
      G00437592Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      NOTICE: 

      • Be careful with the installation direction of the gasket.
      • Do not reuse the gasket.
      • To ensure a proper seal, do not use the tail exhaust pipe to force the gasket onto the front exhaust pipe.

      HINT:  Using a plastic hammer, uniformly strike the gasket so that the gasket and front exhaust pipe are properly fit.

    3. Install 3 new gaskets and front exhaust pipe assembly.
      4. CAUTION: Do not reuse the gaskets.
    4. Install the 2 bolts and 2 compression springs. Torque: 43 Nm (438 kgfcm, 32 ftlbf)
      5. Fig 6: Locating Exhaust Pipe Compression Springs
      G00437586Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install 4 new nuts and 4 bolts. Torque: 62 Nm (632 kgfcm, 46 ftlbf).

      6. NOTICE:  Do not reuse the nuts.

    5. Fig 7: Locating Exhaust Pipe Bolts
    G00437585Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL HEATED OXYGEN SENSOR (for 2WD)  
    1. Before installing the heated oxygen sensors, twist the sensor wires counterclockwise 4 turns.
      2. Fig 8: Twisting Sensor Wires
      G00437593Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using the SST, install the heated oxygen sensors to the front exhaust pipe. SST: 09224-00010. Torque: 44 Nm (449 kgfcm, 33 ftlbf).
      3. Fig 9: Installing Heated Oxygen Sensors
      G00437594Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. After installing the sensors, check that the sensor wires are not twisted. If the sensor wires are twisted, reinstall them.
    4. Install the grommets of the heated oxygen sensors.
      5. Fig 10: Locating Heated Oxygen Sensor Grommets
      G00437581Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL HEATED OXYGEN SENSOR (for 4WD)  
    1. Before installing the sensors, twist the sensor wires counterclockwise 4 turns.
      2. Fig 11: Twisting Sensor Wires
      G00437593Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using the SST, install the heated oxygen sensors to the front exhaust pipe. SST: 09224-00010. Torque: 44 Nm (449 kgfcm, 33 ftlbf).
      3. Fig 12: Installing Heated Oxygen Sensors
      G00437594Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. After installing the sensors, check that sensor wires are not twisted. If the sensor wires are twisted, reinstall them.
    4. Install the grommets of heated oxygen sensors.
      5. Fig 13: Locating Heated Oxygen Sensors (4WD)
      G00437583Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL FRONT CENTER FLOOR BRACE 
    1. Install the front center floor brace with the 4 bolts. Torque: 7.4 Nm (75 kgfcm, 65 inlbf).
      2. Fig 14: Locating Front Center Floor Brace
      G00437580Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL REAR NO. 1 FLOOR PANEL BRACE 
    1. Install the rear No. 1 floor panel brace with the 4 bolts. Torque: 19 Nm (194 kgfcm, 14 ftlbf).
      2. Fig 15: Locating Rear No. 1 Floor Panel Brace
      G00437579Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. CHECK FOR EXHAUST GAS LEAKS 
    1. If exhaust gas is leaking, tighten the related parts to stop the leak. Replace damaged parts as necessary.
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