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INSTALLATION (To 8/2009): Installation

  1. INSTALL NO. 2 OXYGEN SENSOR (for Bank 2 Sensor 2)  . Refer to INSTALLATION - Step 1
  2. INSTALL FRONT EXHAUST PIPE ASSEMBLY 
    1. Install a new gasket to the front exhaust pipe assembly.
    2. Install the front exhaust pipe assembly with the 2 nuts and 2 bolts (B).
      Fig 1: Install The Front Exhaust Pipe Assembly With The 2 Nuts And 2 Bolts (B)
      GTY271454Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bolt B 

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

      Nut 

      Torque: 55 N*m (561 kgf*cm, 40 ft.*lbf) 

    3. Tighten the bolt (A).

      Bolt A 

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

    4. Connect the No. 2 oxygen sensor connector (for Bank 2 Sensor 2).
      Fig 2: Connect The No. 2 Oxygen Sensor Connector (For Bank 2 Sensor 2)
      GTY255609Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY 
    1. Install 2 new gaskets to the front No. 3 exhaust pipe sub-assembly.
    2. Install the front No. 3 exhaust pipe sub-assembly with the 2 bolts and 2 nuts.
      Fig 3: Install The Front No. 3 Exhaust Pipe Sub-Assembly With The 2 Bolts And 2 Nuts
      GTY283031Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bolt 

      Torque: 55 N*m (561 kgf*cm, 40 ft.*lbf) 

      Nut 

      Torque: 55 N*m (561 kgf*cm, 40 ft.*lbf) 

  4. INSTALL OXYGEN SENSOR (for Bank 1 Sensor 2)  . Refer to INSTALLATION - Step 4
  5. INSTALL CENTER EXHAUST PIPE ASSEMBLY 
    1. Using a vernier caliper, measure the free length of the compression springs.
      Fig 4: Measuring Free Length Of Compression Spring
      GTY104505Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Minimum length

      41.5 mm (1.64 in.)

      If the free length is less than the minimum, replace the compression spring.

    2. Fully insert a new gasket to the front No. 3 exhaust pipe sub-assembly.
    3. Using a plastic hammer and wooden block, tap in the new gasket until its surface is flush with the front No. 3 exhaust pipe sub-assembly.
      Fig 5: Identifying Front No. 3 Exhaust Pipe Sub-Assembly, Wooden Block And Gasket
      GTY288335Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Front No. 3 Exhaust Pipe Sub-assembly
      *2 Gasket
      *3 Wooden Block
      NOTE:
      • Be sure to install the gasket in the correct direction.
      • Do not reuse the gasket.
      • Do not damage the gasket.
      • Do not push in the gasket by using the exhaust pipe when connecting it.
    4. Connect the center exhaust pipe assembly to the 2 exhaust pipe supports.
    5. Install the center exhaust pipe assembly with the 2 bolts and 2 compression springs.
      Fig 6: Install The Center Exhaust Pipe Assembly With The 2 Bolts And 2 Compression Springs
      GTY261109Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 43 N*m (440 kgf*cm, 32 ft.*lbf) 

  6. INSTALL TAIL EXHAUST PIPE ASSEMBLY 
    1. Using a vernier caliper, measure the free length of the compression springs.
      Fig 7: Measuring Free Length Of Compression Spring
      GTY104505Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Minimum length

      38.5 mm (1.52 in.)

      If the free length is less than the minimum, replace the compression spring.

    2. Fully insert a new gasket to the center exhaust pipe assembly.
    3. Using a plastic hammer and wooden block, tap in the new gasket until its surface is flush with the center exhaust pipe assembly.
      Fig 8: Identifying Center Exhaust Pipe Assembly, Wooden Block And Gasket
      GTY238166Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Center Exhaust Pipe Assembly
      *2 Gasket
      *3 Wooden Block
      NOTE:
      • Be sure to install the gasket in the correct direction.
      • Do not reuse the gasket.
      • Do not damage the gasket.
      • Do not push in the gasket by using the exhaust pipe when connecting it.
    4. Connect the tail exhaust pipe assembly to the 4 exhaust pipe supports.
    5. Install the tail exhaust pipe assembly with the 2 bolts and 2 compression springs.
      Fig 9: Install The Tail Exhaust Pipe Assembly With The 2 Bolts And 2 Compression Springs
      GTY266946Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 43 N*m (440 kgf*cm, 32 ft.*lbf) 

  7. INSTALL EXHAUST PIPE DAMPER 
    1. Install the 2 exhaust pipe dampers with the 4 bolts.
      Fig 10: Install The 2 Exhaust Pipe Dampers With The 4 Bolts
      GTY255494Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  8. INSTALL FRONT FLOOR COVER LH  See step  13
  9. INSPECT FOR EXHAUST GAS LEAK 
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