Exhaust Pipe: Installation

WARNING: This page is about a different car, the 2008 Lexus IS 350. However, it is still accessible from the selected car via links, so may be relevant.

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. Using a plastic hammer, uniformly tap the tail exhaust pipe baffle sub-assemblies onto the tail exhaust pipe assembly.
  
  Fig 1: Tapping Tail Exhaust Pipe Baffle Sub-Assemblies Onto Tail Exhaust Pipe Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL EXHAUST PIPE DAMPER
1. Install the exhaust pipe damper with the 2 bolts.
  Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)
  
  Fig 2: Locating Exhaust Pipe Damper Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TAIL EXHAUST PIPE ASSEMBLY
1. Install the tail exhaust pipe assembly with the 6 exhaust pipe supports.
  
  Fig 3: Locating Exhaust Pipe Supports
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  
  Fig 4: Measuring Free Length Of Compression Springs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install a new gasket to the rear end of the front exhaust pipe assembly.
  NOTE:
  - 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 2 new gaskets and front exhaust pipe assembly.
  NOTE: Do not reuse the gaskets.
  
  Fig 5: Identifying Gasket On Rear End Of Front Exhaust Pipe Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the 2 bolts and 2 compression springs.
  Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
  
  Fig 6: Locating Bolts And Compression Springs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the 4 nuts and 4 bolts.
  Torque: 32 N*m (398 kgf*cm, 29 ft.*lbf)
  
  NOTE: Do not reuse the gaskets and nuts.
  
  Fig 7: Locating Nuts And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL HEATED OXYGEN SENSOR
1. Before installing the heated oxygen sensors, twist the sensor wires counterclockwise 4 turns.
  
  Fig 8: Twisting Sensor Wires Counterclockwise
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using the SST, install the heated oxygen sensors to the front exhaust pipe assembly.
  SST 09224-00010
  
  Torque: 44 N*m (449 kgf*cm, 33 ft.*lbf)
3. After installing the sensors, check that the sensor wires are not twisted.
  If the sensor wires are twisted, reinstall them.
  
  Fig 9: Installing Heated Oxygen Sensors To Front Exhaust Pipe Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the grommets of the heated oxygen sensors.
  
  Fig 10: Identifying Grommets Of Heated Oxygen Sensors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT CENTER FLOOR BRACE
1. Install the front center floor brace with the 4 bolts.
  Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
  
  Fig 11: Locating Front Center Floor Brace Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR NO. 1 FLOOR PANEL BRACE
1. Install the rear No. 1 floor panel brace with the 4 bolts.
  Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)
CHECK FOR EXHAUST GAS LEAKS
If exhaust gas is leaking, tighten the related parts to stop the leak. Replace damaged parts as necessary.

Fig 12: Locating Rear No. 1 Floor Panel Brace Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002