Exhaust Pipe And Catalytic Converter: Installation

WARNING: This page is about a different car, the 2008 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL FRONT EXHAUST PIPE ASSEMBLY
1. Using a vernier caliper, measure the free length of the compression spring.
  Minimum length:
  
  41.5 mm (1.634 in.)
  
  If the length is less than the minimum, replace the compression spring.
  
  Fig 1: Measuring Free Length Of Compression Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install a new gasket by hand so that its surface is flush with the exhaust manifold.
  NOTE:
  - Make sure the gasket is facing the correct direction.
  - Do not reuse the removed gasket.
  - Do not push in the gasket while installing the front exhaust pipe.
3. Install the front exhaust pipe with the 2 compression springs and 2 bolts.
  Torque: 43 Nm (438 kgf.cm, 32 ft.lbf)
  
  Fig 2: Installing Front Exhaust Pipe With Compression Springs And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 3: Installing Gasket Onto Front Exhaust Pipe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CENTER EXHAUST PIPE ASSEMBLY
1. Install a new gasket onto the front exhaust pipe.
2. Connect the 3 exhaust pipe supports, and install the center exhaust pipe.
3. Install the 2 bolts.
  Torque: 43 Nm (438 kgf.cm, 32 ft.lbf)
  
  Fig 4: Installing Gasket Onto Front Exhaust Pipe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 5: Installing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TAILPIPE ASSEMBLY
1. Using a vernier caliper, measure the free length of the compression spring.
  Minimum length:
  
  38.5 mm (1.516 in.)
  
  If the length is less than the minimum, replace the compression spring.
  
  Fig 6: Measuring Free Length Of Compression Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install a new gasket by hand so that its surface is flush with the center exhaust pipe.
  
  Fig 7: Installing Exhaust Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Make sure the gasket is facing the correct direction.
  - Do not reuse the removed gasket.
  - Do not push in the gasket while installing the tailpipe.
3. Connect the 2 exhaust pipe supports, and install the tailpipe.
  
  Fig 8: Installing Tailpipe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the 2 compression springs and 2 bolts.
  Torque: 43 Nm (438 kgf.cm, 32 ft.lbf)
INSTALL HEATED OXYGEN SENSOR (for Bank 1 Sensor 2) (See INSTALLATION )
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
CHECK FOR EXHAUST GAS LEAKS
If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.