Installation [03/2019 - ]: Procedure

INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY

WARNING:

Hot exhaust system.
Risk of burning!
- Any work must exclusively be carried out with an exhaust system that has cooled down.
Heavy component.
Heavy components can lead to injury or damage.
- Remove and install heavy components with the aid of another person/other persons.

HINT:

If the separation point is not marked by a punch mark in the pipe, determine the separation point by means of the pipe length on the new component.
Transfer the separation point to the faulty component and mark.
Cut through the faulty component at the marked point with a suitable tool.
Deburr the separation point and remove any swarf. There is a risk of remaining metal chips at the joint between the two pipes and/or swarf in the rear silencer.
Check the exhaust system for tightness after installation.

for V-band Clamp:

Release the nut (1) and remove the sealing ring (2).

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Mount the sealing ring (1) on the exhaust pipe assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Ensure that the sealing ring (1) is correctly positioned for the exhaust pipe clamp (2).

Bend all sheet metal tabs over with a suitable tool, except those in the marked areas.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Mount the exhaust pipe clamp (1) on the sealing ring (2).

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Make sure that the exhaust pipe clamp (1) is positioned correctly on the sealing ring (2).

Make sure that the V-band clamprests against the sheet metal tabs after mounting (marks).

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Connect the front No. 2 exhaust pipe assembly (1) with the exhaust manifold converter sub-assembly (2) and position correctly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a 16 mm deep socket wrench, tighten down screw (2).

NOTE:

Make sure that exhaust pipe clamp (1) is fitted correctly.

Torque: 25 N.m (255 kgf/cm, 18 ft.lbf)

Connect the front No. 2 exhaust pipe assembly to the rear silencer with the front No. 1 exhaust pipe clamp (for Rear) (2).

Center the front No. 1 exhaust pipe clamp (for Rear) (2) and tighten the nuts (1).
Torque: 45 N.m (459 kgf/cm, 33 ft.lbf)

for Ribbon Clamp:

Open the weld seam (1) with a hacksaw.

Remove the exhaust pipe clamp (2).
Replace the exhaust pipe clamp.
Have someone help insert the front No. 2 exhaust pipe assembly and position it at the front.
Tighten the exhaust pipe clamp.
Torque: 26 N.m (265 kgf/cm, 19 ft.lbf)
Have someone help position the front No. 2 exhaust pipe assembly in the center.
Check the rubber mounts for damage and replace, if necessary.
Replace nut.
Tighten the nut on the holder.
Torque: 19 N.m (194 kgf/cm, 14 ft.lbf)

Connect the front No. 2 exhaust pipe assembly to the rear silencer with the front No. 1 exhaust pipe clamp (for Rear) (2).

Engage the front No. 1 exhaust pipe clamp (for Rear) (2) and tighten the nuts (1).
Torque: 45 N.m (459 kgf/cm, 33 ft.lbf)

INSTALL REAR FLOOR PANEL BRACE
See step 4
INSTALL REAR FLOOR SIDE MEMBER COVER LH
See step 5
INSTALL REAR FLOOR SIDE MEMBER COVER RH
HINT:

Use the same procedure as for the LH side.
INSPECT FOR EXHAUST GAS LEAK
See step 7