Exhaust Pipe: Service and Repair

EXHAUST PIPE ASSEMBLY (2AZ-FE)
Removal & Installation and Disassembly & Reassembly





NOTICE: When disconnecting the battery terminal, initialize the system(s) shown after the terminal is reconnected.

1. DISCONNECT BATTERY NEGATIVE TERMINAL
2. REMOVE HEATED OXYGEN SENSOR
SST 09224-00010





3. REMOVE FLOOR PANEL BRACE FRONT
a. Remove the 4 bolts, then remove the floor panel brace front.





4. REMOVE EXHAUST PIPE ASSEMBLY TAIL
a. Remove the 2 bolts and 2 compression springs.
b. Remove the exhaust pipe tail from the 3 exhaust pipe supports No. 4.





c. Remove the gasket from the exhaust pipe center.





5. REMOVE EXHAUST PIPE ASSEMBLY CENTER
a. Remove the 2 bolts.
b. Remove the exhaust pipe center from the 2 exhaust pipe supports No. 4.





c. Remove the gasket from the exhaust pipe front.





6. REMOVE EXHAUST PIPE ASSEMBLY FRONT
a. Remove the 2 bolts and 2 compression springs, then remove the exhaust pipe front.





b. Remove the gasket from the exhaust manifold.





7. REMOVE EXHAUST PIPE SUPPORT NO.4
a. Remove the 5 exhaust pipe supports from the body.





8. REMOVE EXHAUST TAIL PIPE BAFFLE SUB-ASSEMBLY
a. Using a plastic faced hammer, uniformly tap the exhaust tail pipe baffle to remove.





9. INSTALL EXHAUST TAIL PIPE BAFFLE SUB-ASSEMBLY
a. Align the keyway of the exhaust tail pipe baffle with the key located on the exhaust pipe tail.
b. Using a plastic faced hammer, uniformly tap the exhaust tail pipe baffle to install.





10. INSTALL EXHAUST PIPE SUPPORT NO.4
a. Install the 5 exhaust pipe supports into the body.





11. INSTALL EXHAUST PIPE ASSEMBLY FRONT
a. Check the free length.
1. Using vernier calipers, measure the free length of the compression spring.
Minimum: 40.5 mm (1.594 inch)
If the free length is less than minimum, replace the compression spring.





b. Using a wooden block and plastic faced hammer, tap a new gasket until it is flash with the exhaust manifold.

NOTICE:
- Make sure that the gasket is in the correct direction when installing.
- Do not reuse a removed gasket.
- Never push the gasket into the exhaust manifold by installing the exhaust pipe front onto exhaust manifold.





c. Install the exhaust pipe front with the 2 compression springs and 2 bolts.
Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.)





12. INSTALL EXHAUST PIPE ASSEMBLY CENTER
a. Install a new gasket onto the exhaust pipe front.





b. Install the exhaust pipe center onto the 2 exhaust pipe supports No. 4.
c. Tighten the 2 bolts.
Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.)





13. INSTALL EXHAUST PIPE ASSEMBLY TAIL
a. Check the free length.
1. Using vernier calipers, measure the free length of the compression spring.
Minimum: 38.5 mm (1.516 inch)
If the free length is less than minimum, replace the compression spring.





b. Using a wooden block and plastic faced hammer, tap a new gasket until it is flash with the exhaust pipe center.

NOTICE:
- Make sure that the gasket is in the correct direction when installing.
- Do not reuse a removed gasket.
- Never push the gasket onto the exhaust pipe center by installing the exhaust pipe tail onto the exhaust pipe center.





c. Install the exhaust pipe tail to the 3 exhaust pipe supports.
d. Tighten the 2 compression springs and 2 bolts.
Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.)
14. INSTALL HEATED OXYGEN SENSOR
SST 09224-00010
15. CONNECT BATTERY NEGATIVE TERMINAL
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
16. CHECK FOR EXHAUST GAS LEAKAGE





17. INSTALL FLOOR PANEL BRACE FRONT
a. Install the floor panel brace front with the 4 bolts.
Torque: 29.6 Nm (300 kgf-cm, 22 ft. lbs.)

NOTICE: Make sure that the floor panel brace front is at the correct direction when installing.