Exhaust Pipe Installation

Engine. Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35
3Zr-Fae Exhaust. Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. INSTALL FRONT EXHAUST PIPE ASSEMBLY

  2. INSTALL CENTER EXHAUST PIPE ASSEMBLY

  3. INSTALL TAILPIPE ASSEMBLY

  4. CONNECT HEATED OXYGEN SENSOR

  5. INSPECT FOR EXHAUST GAS LEAK

Exhaust Pipe -- Installation



1. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.3Zr-Fae Exhaust.Exhaust Manifold.Exhaust Pipe  Installation
  1. Using a vernier caliper, measure the free length of the compression spring.

    Minimum length:
    41.5 mm (1.63 in.)
    If the length is less than the minimum, replace the compression spring.
  1. Using a wire brush, remove any foreign matter from the gasket installation surface.



    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.3Zr-Fae Exhaust.Exhaust Manifold.Exhaust Pipe  Installation
  1. Install a new gasket by hand so that its surface is flush with the exhaust manifold.

    NOTICE:
    1. Make sure the gasket is facing the correct direction.
    2. Do not reuse the removed gasket.
    3. Do not push in the gasket while installing the front exhaust pipe.


  1. Install the front exhaust pipe and 2 compression springs with the 2 bolts.

    Torque:
    43 N*m{438 kgf*cm, 32 ft.*lbf}


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.3Zr-Fae Exhaust.Exhaust Manifold.Exhaust Pipe  Installation



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

  1. Connect the 3 exhaust pipe supports to install the center exhaust pipe.



  1. Install the 2 bolts.

    Torque:
    43 N*m{438 kgf*cm, 32 ft.*lbf}


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.3Zr-Fae Exhaust.Exhaust Manifold.Exhaust Pipe  Installation



3. INSTALL TAILPIPE ASSEMBLY


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.3Zr-Fae Exhaust.Exhaust Manifold.Exhaust Pipe  Installation
  1. Using a vernier caliper, measure the free length of the compression spring.

    Minimum length:
    38.5 mm (1.52 in.)
    If the length is less than the minimum, replace the compression spring.


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.3Zr-Fae Exhaust.Exhaust Manifold.Exhaust Pipe  Installation
  1. Install a new gasket by hand so that its surface is flush with the center exhaust pipe.

    NOTICE:
    1. Make sure the gasket is facing the correct direction.
    2. Do not reuse the removed gasket.
    3. Do not push in the gasket while installing the tailpipe.
  1. Connect the 2 exhaust pipe supports to install the tailpipe.



  1. Install the 2 compression springs and 2 bolts.

    Torque:
    43 N*m{438 kgf*cm, 32 ft.*lbf}


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.3Zr-Fae Exhaust.Exhaust Manifold.Exhaust Pipe  Installation



4. CONNECT HEATED OXYGEN SENSOR
NOTICE:
Do not strike the metal part of the sensor.
  1. Rotate the sensor counterclockwise the same number of times as recorded in the removal procedure, and then connect it to the front exhaust pipe by hand.

    NOTICE:
    After rotating the sensor counterclockwise the same number of times as in the removal procedure, connect it while making sure that the wire harness is not twisted.


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.3Zr-Fae Exhaust.Exhaust Manifold.Exhaust Pipe  Installation
  1. Using SST, tighten the sensor.

    SST
    09224-00010
    Torque:
    with SST:
    40 N*m{408 kgf*cm, 30 ft.*lbf}
    without SST:
    44 N*m{449 kgf*cm, 32 ft.*lbf}
    HINT:
    1. Make sure SST and the wrench are connected in a straight line.
    2. Use a torque wrench with a fulcrum length of 300 mm (11.8 in.).
  1. Connect the grommet to the floor panel.



5. INSPECT FOR EXHAUST GAS LEAK
If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.