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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 (for 2WD) 
    1. Install the bracket with the 2 bolts.

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

      Fig 1: Locating No. 1 Exhaust Pipe Support Bracket Bolts
      G04943772Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL EXHAUST PIPE DAMPER 
    1. Install the damper to the tailpipe LH with 2 new bolts.

      Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) 

      NOTE: Do not reuse the 2 removed bolts.
      Fig 2: Locating Exhaust Pipe Damper Bolts - LH
      G05773281Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the damper to the tailpipe RH with 2 new bolts.

      Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) 

      NOTE: Do not reuse the 2 removed bolts.
      Fig 3: Locating Exhaust Pipe Damper Bolts - RH
      G05773286Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL TAILPIPE RH 
    1. Connect the 3 exhaust pipe supports to install the tailpipe.
      Fig 4: Locating Exhaust Pipe Supports Correct And Incorrect Installation Position - RH
      G05773287Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL TAILPIPE LH 
    1. Connect the 3 exhaust pipe supports to install the tailpipe.
      Fig 5: Locating Exhaust Pipe Supports Correct And Incorrect Installation Position - LH
      G05773288Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL HEATED OXYGEN SENSOR (for AWD) 
    NOTE: Do not strike the metal part of the sensor.
    1. Install the sensor to the exhaust pipe by hand.
      Fig 6: Locating Heated Oxygen Sensor (For AWD)
      G05773289Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, tighten the sensor.

      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) 

      HINT:

      • Make sure SST and the wrench are connected in a straight line.
      • Use a torque wrench with a fulcrum length of 300 mm (11.8 in.).
        Fig 7: Identifying SST Fulcrum Length
        G04943780Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. 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 8: Locating Exhaust Manifold Gaskets
      G04943775Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install 2 new gaskets to the exhaust pipe rear ends.
      Fig 9: Locating Exhaust Pipe Rear Ends 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.

      HINT:

      During installation, hold the front exhaust pipe.

      Fig 10: Locating Front Exhaust Pipe To Exhaust Manifold Bolt And Nuts
      G06196331Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the front exhaust pipe to the tailpipe LH and RH with the 4 bolts.

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

      HINT:

      During installation, hold the front exhaust pipe.

      Fig 11: Locating Exhaust Pipe To Tail Pipe Bolts
      G05773275Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. 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 12: Locating Front Center Floor Brace Bolts
      G05773270Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. CONNECT HEATED OXYGEN SENSOR (for 2WD) 
    NOTE: Do not strike the metal part of the sensor.
    1. Rotate the sensors counterclockwise the same number of times as recorded in the removal procedure, and install then to the front exhaust pipe by hand.
      NOTE: After rotating the sensor counterclockwise the same number of times as the removal procedure, install it while making sure that the wire harness is not twisted.
      Fig 13: Rotating Sensor Counterclockwise
      G04943779Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, tighten the 2 sensors.

      Torque: with SST 

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

      without SST 

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

      SST 09224-00010 

      Fig 14: Connecting Heated Oxygen Sensor Using SST (For 2WD)
      G06196310Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      • Make sure SST and the wrench are connected in a straight line.
      • Use a torque wrench with a fulcrum length of 300 mm (11.8 in.).
    3. Connect the 2 grommets to the floor panel.
      Fig 15: Identifying SST Fulcrum Length
      G04943780Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. CONNECT HEATED OXYGEN SENSOR (for AWD) 
    1. Connect the sensor connector.
      Fig 16: Locating Exhaust Gas Temperature Sensor Connector
      G05773273Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Rotate the sensor counterclockwise the same number of times as recorded in the removal procedure, and install it to the front exhaust pipe by hand.
      NOTE: After rotating the sensor counterclockwise the same number of times as the removal procedure, install it while making sure that the wire harness is not twisted.
      Fig 17: Rotating Sensor Counterclockwise
      G04943779Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, tighten the sensor.

      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) 

      HINT:

      • Make sure SST and the wrench are connected in a straight line.
      • Use a torque wrench with a fulcrum length of 300 mm (11.8 in.).
      Fig 18: Identifying SST Fulcrum Length
      G05771281Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the grommet to the floor panel.
  10. INSPECT FOR EXHAUST GAS LEAK 
    1. If gas is leaking, tighten the areas necessary to stop the leak. Replace the damaged parts as necessary.
  11. INSTALL FRONT CENTER FLOOR COVER (for AWD)  (See INSTALLATION )
  12. INSTALL FRONT FLOOR COVER RH 
    1. Install the cover with the 3 hole seals and 4 grommets.
      Fig 19: Locating Front Floor Cover Hole Seals And Grommets - RH
      G05773301Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL FRONT FLOOR COVER LH 
    1. Install the cover with the 3 hole seals and 4 grommets.
      Fig 20: Locating Front Floor Cover Hole Seals And Grommets - LH
      G05773302Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL REAR FLOOR SIDE MEMBER COVER RH 
    1. Install the cover with the clip, nut, 3 bolts and 2 screws.

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

      Fig 21: Locating Rear Floor Side Member Cover Clip, Nut, Screws And Bolts - LH
      G05773267Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE REAR FLOOR SIDE MEMBER COVER LH 
    1. Install the cover with the clip, nut, 3 bolts and 2 screws.

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

  16. INSTALL NO. 5 ROCKER PANEL MOLDING PROTECTOR 
    1. Install the protector with the 2 clips and screw.
  17. INSTALL NO. 6 ROCKER PANEL MOLDING PROTECTOR 
    1. Install the protector with the 2 clips and screw.
      Fig 22: Locating Rear Floor Side Member Cover Clip, Nut, Screws And Bolts - RH
      G05773266Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL NO. 1 DIFFERENTIAL SUPPORT PROTECTOR  (See INSTALLATION )
  19. INSTALL NO. 2 DIFFERENTIAL SUPPORT PROTECTOR  (See INSTALLATION )
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