Engine Exhaust Assembly: Replacement

NOTE: Check if an old gasket still remains on the pipe. If so, remove it. Also, check if any bolts or nuts are rusted. If so, replace them.

REMOVE HEATED OXYGEN SENSOR
1. Disconnect the 2 heated oxygen sensor (bank 1, 2 sensor 2) connectors.
2. Remove the 2 heated oxygen sensors (bank 1, 2 sensor 2).
REMOVE FRONT EXHAUST PIPE NO. 1 SUPPORT BRACKET
1. Remove the 2 nuts and front support brackets.
REMOVE REAR EXHAUST PIPE NO. 1 SUPPORT BRACKET
1. Remove the 2 bolts and rear support bracket.
REMOVE EXHAUST PIPE ASSY FRONT
1. Remove the 2 nuts from the exhaust pipe front (left bank exhaust manifold side).
2. Remove the 2 bolts from the exhaust pipe front (right bank exhaust manifold side).
3. Remove the 2 nuts and 2 bolts from the exhaust pipe front (exhaust pipe center side). Then remove the exhaust pipe front.
4. Remove the 3 gaskets from the exhaust pipe front.
  
  Fig 1: Removing Exhaust Pipe Assy Front
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EXHAUST PIPE ASSY CENTER
1. Remove the 4 nuts from the 2 exhaust pipe tails.
2. Disconnect the 2 exhaust pipe supports and remove the exhaust pipe center.
3. Remove the 2 gaskets from the exhaust pipe center.
4. Remove the 2 bolts from the exhaust pipe damper.
REMOVE EXHAUST PIPE ASSY TAIL
1. Disconnect the 5 exhaust pipe supports and remove the 2 exhaust pipe tails.
REMOVE EXHAUST TAIL PIPE BAFFLE SUB ASSY
1. Using a plastic hammer, tap out the baffles uniformly to remove them from each exhaust pipe tail.
  
  Fig 2: Removing Exhaust Tail Pipe Baffle Sub Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL EXHAUST TAIL PIPE BAFFLE SUB ASSY
1. Align the groove on the exhaust tail pipe baffle with the projection on the exhaust pipe tail.
  
  Fig 3: Installing Exhaust Tail Pipe Baffle Sub Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL EXHAUST PIPE ASSY TAIL
1. Connect the 5 exhaust pipe supports and install the 2 exhaust pipe tails.
INSTALL EXHAUST PIPE ASSY CENTER
1. Install the exhaust pipe damper to the exhaust pipe center with the 2 bolts.
  Torque: 19 N.m (194 kgf.cm, 14 ft.lbf)
2. Install 2 new gaskets between the exhaust pipe center and exhaust pipe tails.
3. Connect the 2 exhaust pipe supports and install the exhaust pipe center.
4. Install the exhaust pipe center to the 2 exhaust pipe tails with the 4 nuts.
  Torque: 43 N.m (438 kgf.cm, 32 ft.lbf)
INSTALL EXHAUST PIPE ASSY FRONT
1. Install 3 new gaskets to the exhaust pipe fronts.
2. Install the exhaust pipe front to the exhaust manifolds with the 2 nuts and 2 bolts.
  Torque: 62 N.m (632 kgf.cm, 46 ft.lbf)
3. Install the exhaust pipe front to the exhaust pipe center with the 2 nuts and 2 bolts.
  Torque: 56 N.m (571 kgf.cm, 41 ft.lbf)
INSTALL REAR EXHAUST PIPE NO. 1 SUPPORT BRACKET
1. Install the rear support bracket with the 2 bolts.
  Torque: 33 N.m (337 kgf.cm, 24 ft.lbf)
  
  NOTE: Be sure to install the bracket in the correct direction.
  
  Fig 4: Installing Rear Support Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT EXHAUST PIPE NO. 1 SUPPORT BRACKET
1. Install the front support brackets with the 2 nuts.
  Torque: 33 N.m (337 kgf.cm, 24 ft.lbf)
  
  NOTE: Be sure to install the support bracket in the correct direction.
  
  Fig 5: Installing Front Support Brackets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL HEATED OXYGEN SENSOR
1. Install the 2 heated oxygen sensors (bank 1, 2 sensor 2).
  Torque: 44 N.m (449 kgf.cm, 32 ft.lbf)
2. Connect the 2 heated oxygen sensor (bank 1, 2 sensor 2) connectors.
  
  Fig 6: Installing Heated Oxygen Sensor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK FOR EXHAUST GAS LEAKS
If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.