Installation [08/2015 - 10/2016]: Procedure

HINT: 

• Perform this procedure only when replacement of the tail exhaust pipe baffle sub-assembly is necessary.
• If the tail exhaust pipe baffle sub-assembly is removed, replace it with a new one.

1. Align the cutout of a new tail exhaust pipe baffle sub-assembly with the protrusion (for position alignment) of the tail exhaust pipe assembly and tail exhaust pipe LH as shown in the illustration.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Protrusion (for position alignment)
   *b	Protrusion (for stopper)
   *c	Cutout

2. Insert the tail exhaust pipe baffle sub-assembly to the position where it can be pressed in by hand.
3. Using a plastic-faced hammer and wooden block, uniformly tap the tail exhaust pipe baffle sub-assembly onto the tail exhaust pipe assembly and tail exhaust pipe LH.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Baffle Edge
   *b	Protrusion (for stopper)
   *c	Cutout
   *d	Wooden Block

   NOTE:

   • Lightly tap the top and bottom of the tail exhaust pipe baffle sub-assembly so that the tail exhaust pipe baffle sub-assembly is pressed in without a tilt.
   • Press the tail exhaust pipe baffle sub-assembly in until the protrusion on the tail exhaust pipe assembly and tail exhaust pipe LH is fit into the cutout area of the tail exhaust pipe baffle sub-assembly.
   • Check that there is no looseness in the tail exhaust pipe baffle sub-assembly.

1. Install the tail exhaust pipe LH to the 3 exhaust pipe supports.
   NOTE:

   Protect the rear bumper assembly using protection material such as a piece of cloth to avoid damage by the tail exhaust pipe LH.

1. Install the tail exhaust pipe assembly to the 3 exhaust pipe supports.
   NOTE:

   Protect the rear bumper assembly using protection material such as a piece of cloth to avoid damage by the tail exhaust pipe assembly.

1. Using a vernier caliper, measure the free length of the compression springs.

   Standard Length	40 mm (1.57 in.)
   Minimum Free Length	38.5 mm (1.52 in.)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

2. Temporarily install 2 new exhaust pipe gaskets to the front exhaust pipe assembly for tail exhaust pipe assembly and tail exhaust pipe LH side.
3. Using a plastic hammer and wooden block, tap in each exhaust pipe gasket until its surface is flush with the front exhaust pipe assembly.
   NOTE:

   • Be sure to install the gaskets in the correct direction.
   • Do not reuse the exhaust pipe gaskets.
   • Do not damage the exhaust pipe gaskets.
   • Do not push in the exhaust pipe gaskets by using the front exhaust pipe assembly when connecting it.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Front Exhaust Pipe Assembly
   *2	Exhaust Pipe Gasket
   *a	Wooden Block

4. Install a new exhaust pipe gasket to the front exhaust pipe assembly for exhaust manifold converter sub-assembly (TWC: Front and Rear Catalyst) side.
5. Connect the front exhaust pipe assembly with 2 new nuts and 2 new bolts.

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

6. Install the front exhaust pipe assembly to the tail exhaust pipe assembly and tail exhaust pipe LH with the 4 bolts and 4 compression springs.

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

   HINT: 

   After installation, check that the space between the flanges of the front exhaust pipe assembly and tail exhaust pipe assembly and tail exhaust pipe LH are consistent front-to-rear and left-to-right.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Tail Exhaust Pipe Assembly and Tail Exhaust Pipe LH
   *2	Front Exhaust Pipe Assembly
   *3	Exhaust Pipe Gasket
   *a	Space between Flanges: 6.5 mm (0.256 in.)

Refer to PROCEDURE - Step 77

Refer to PROCEDURE - Step 78

Refer to PROCEDURE - Step 79

If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.

1. Perform Inspection After Repair after repairing an exhaust gas leak.

   Refer to INITIALIZATION [08/2015 - 09/2018]