Exhaust Pipe (W/ Dpf) Installation

Install the 2 No. 1 converter protector stays and 2 No. 2 converter protector stays to the front exhaust pipe.

Install the upper monolithic converter protector and lower monolithic converter protector with the 4 bolts and 4 nuts.

Torque:

11 N*m{107 kgf*cm, 8 ft.*lbf}

Install the exhaust pipe clamp with the bolt, and a new nut.

Torque:

18 N*m{184 kgf*cm, 13 ft.*lbf}

Using a 14 mm union nut wrench, install the No. 3 exhaust gas temperature sensor.

Torque:

30 N*m{306 kgf*cm, 22 ft.*lbf}

NOTICE:

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (HILUX_TGN26 RM000004QR1006X.html).

Install the wiring harness clamp bracket with the bolt.

Torque:

21 N*m{214 kgf*cm, 15 ft.*lbf}

Using a 14 mm union nut wrench, install the No. 2 exhaust gas temperature sensor.

Torque:

30 N*m{306 kgf*cm, 22 ft.*lbf}

NOTICE:

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (HILUX_TGN26 RM000004QR1006X.html).

Attach the 5 clamps.

HINT:

Make sure that the part of the wire harness is as shown in the illustration.

Using a 14 mm union nut wrench, install the exhaust gas temperature sensor.

Torque:

30 N*m{306 kgf*cm, 22 ft.*lbf}

NOTICE:

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (HILUX_TGN26 RM000004QR1006X.html).

HINT:

The sensor should be assembled within 20° of the prescribed position on either side.

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

Minimum free length:

43 mm (1.69 in.)

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

Using a plastic-faced hammer and wooden block, tap on a new gasket until its surface is flush with the front exhaust pipe.

NOTICE:

1. Be sure to install the gasket so that it faces the correct direction.
   
2. Do not reuse the gasket.
   
3. Do not damage the gasket.
   
4. When connecting the exhaust pipe, do not push in the gasket with the exhaust pipe.
   

Install a new gasket and the front exhaust pipe to the No. 2 turbine outlet elbow with 3 new nuts.

Torque:

54 N*m{554 kgf*cm, 40 ft.*lbf}

Connect the front exhaust pipe to the 2 exhaust pipe supports.

Connect the No. 6 exhaust pipe air hose and No. 7 exhaust pipe air hose to the front exhaust pipe with 2 new clips.

Text in Illustration

*1	Clip
*2	Stopper
*a	4 to 10 mm (0.157 to 0.394 in.)
*b	Pink Paint
*c	Blue Paint
	Paint Mark

NOTICE:

1. Align the paint marks of the front exhaust pipe and exhaust pipe air hose and push on the exhaust pipe air hose until it contacts the stopper.
   
2. Make sure the clip is 4 to 10 mm (0.157 to 0.394 in.) from the end of the exhaust pipe air hose when installing the clip.
   
3. Make sure that there is no slack in the exhaust pipe air hose, and that it is not twisted or bent.
   
4. Take care not to damage the inner or outer surface of the exhaust pipe air hose when installing it. If the exhaust pipe air hose is damaged, replace it with a new one.
   

Connect the No. 3 exhaust gas temperature sensor connector and attach the clamp.

Connect the No. 2 exhaust gas temperature sensor connector and attach the clamp.

Connect the exhaust gas temperature sensor connector and attach the clamp.

Using SST, install the air fuel ratio sensor to the front exhaust pipe.

SST

09224-00010

Torque:

without SST:

44 N*m{449 kgf*cm, 32 ft.*lbf}

with SST:

40 N*m{408 kgf*cm, 30 ft.*lbf}

HINT:

1. Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification (HILUX_TGN26 RM000004QR1006X.html).
   
2. Make sure SST and the wrench are connected in a straight line.
   

Connect the air fuel ratio sensor connector.

for 2WD:
Attach the clamp.

Install the No. 2 exhaust pipe support bracket with the 2 bolts.

Torque:

19 N*m{194 kgf*cm, 14 ft.*lbf}

Install the No. 3 frame crossmember sub-assembly with the 4 bolts and 4 nuts.

Torque:

50 N*m{510 kgf*cm, 37 ft.*lbf}

Connect the No. 3 frame crossmember sub-assembly to the No. 1 rear engine mounting insulator.

Torque:

27 N*m{275 kgf*cm, 20 ft.*lbf}

Install the center exhaust pipe to the 3 exhaust pipe supports.

Install the center exhaust pipe and 2 compression springs with the 2 bolts.

Torque:

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

Install the tailpipe to the exhaust pipe support.

Install a new gasket and connect the tailpipe to the center exhaust pipe with the 2 bolts and 2 nuts. Alternately tighten the bolts in several passes.

Torque:

48 N*m{489 kgf*cm, 35 ft.*lbf}

NOTICE:

Do not reuse the gasket.