Exhaust Pipe Installation

Engine. Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35
2Gr-Fe Exhaust. Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. INSTALL FRONT EXHAUST PIPE ASSEMBLY

  2. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET

  3. INSTALL CENTER EXHAUST PIPE ASSEMBLY

  4. INSTALL NO. 2 EXHAUST PIPE SUB-ASSEMBLY

  5. INSTALL TAIL PIPE ASSEMBLY

  6. INSTALL OXYGEN SENSOR (for Bank 2)

  7. INSTALL OXYGEN SENSOR (for Bank 1)

  8. INSTALL REAR CONSOLE BOX SUB-ASSEMBLY

  9. INSPECT FOR EXHAUST GAS LEAK

Exhaust Pipe -- Installation



1. INSTALL FRONT EXHAUST PIPE ASSEMBLY
  1. Install a new gasket.



  1. Install the front exhaust pipe assembly with the 2 nuts.


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.2Gr-Fe Exhaust.Exhaust Pipe.Exhaust Pipe  Installation

    Torque:
    62 N*m{632 kgf*cm, 46 ft.*lbf}


2. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET
  1. Install the No. 1 exhaust pipe support bracket with the 2 bolts.

    Torque:
    21 N*m{214 kgf*cm, 16 ft.*lbf}


3. INSTALL CENTER EXHAUST PIPE ASSEMBLY
  1. Install 2 new gaskets.



  1. Install the center exhaust pipe assembly with the 2 bolts and 2 nuts.


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.2Gr-Fe Exhaust.Exhaust Pipe.Exhaust Pipe  Installation

    Torque:
    43 N*m{440 kgf*cm, 32 ft.*lbf}


4. INSTALL NO. 2 EXHAUST PIPE SUB-ASSEMBLY


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.2Gr-Fe Exhaust.Exhaust Pipe.Exhaust Pipe  Installation
  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.
  1. Fully insert a new gasket to the center exhaust pipe assembly.



    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.2Gr-Fe Exhaust.Exhaust Pipe.Exhaust Pipe  Installation
  1. Using a plastic hammer and wooden block, tap in the new gasket until its surface is flush with the center exhaust pipe assembly.

    NOTICE:
    1. Be sure to install the gasket in the correct direction.
    2. Do not reuse the gasket.
    3. Do not damage the gasket.
    4. Do not push in the gasket by using the exhaust pipe when connecting it.
  1. Connect the No. 2 exhaust pipe sub-assembly to the 3 exhaust pipe supports.



  1. Install the No. 2 exhaust pipe sub-assembly with the 2 bolts and 2 compression springs.


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.2Gr-Fe Exhaust.Exhaust Pipe.Exhaust Pipe  Installation

    Torque:
    43 N*m{440 kgf*cm, 32 ft.*lbf}


5. INSTALL TAIL PIPE ASSEMBLY


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.2Gr-Fe Exhaust.Exhaust Pipe.Exhaust Pipe  Installation
  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.
  1. Fully insert a new gasket to the No. 2 exhaust pipe sub-assembly.



    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.2Gr-Fe Exhaust.Exhaust Pipe.Exhaust Pipe  Installation
  1. Using a plastic hammer and wooden block, tap in the new gasket until its surface is flush with the No. 2 exhaust pipe sub-assembly.

    NOTICE:
    1. Be sure to install the gasket in the correct direction.
    2. Do not reuse the gasket.
    3. Do not damage the gasket.
    4. Do not push in the gasket by using the exhaust pipe when connecting it.
  1. Connect the tail pipe assembly to the 2 exhaust pipe supports.



  1. Install the tail pipe assembly with the 2 bolts and 2 compression springs.


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.2Gr-Fe Exhaust.Exhaust Pipe.Exhaust Pipe  Installation

    Torque:
    43 N*m{440 kgf*cm, 32 ft.*lbf}


6. INSTALL OXYGEN SENSOR (for Bank 2)


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.2Gr-Fe Exhaust.Exhaust Pipe.Exhaust Pipe  Installation
  1. Using SST, install the sensor to the exhaust pipe.

    SST
    09224-00010
    Torque:
    40 N*m{408 kgf*cm, 30 ft.*lbf} for use with SST
    44 N*m{449 kgf*cm, 32 ft.*lbf} for use without SST
    HINT:
    1. Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
    2. Make sure that SST and a wrench are connected in a straight line.
  1. Connect the sensor connector.



7. INSTALL OXYGEN SENSOR (for Bank 1)


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.2Gr-Fe Exhaust.Exhaust Pipe.Exhaust Pipe  Installation
  1. Using SST, install the sensor to the exhaust pipe.

    SST
    09224-00010
    Torque:
    40 N*m{408 kgf*cm, 30 ft.*lbf} for use with SST
    44 N*m{449 kgf*cm, 32 ft.*lbf} for use without SST
    HINT:
    1. Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
    2. Make sure that SST and a wrench are connected in a straight line.
  1. Connect the sensor connector.



8. INSTALL REAR CONSOLE BOX SUB-ASSEMBLY
(RAV4_ACA30 RM000001RHG00HX.html)


9. INSPECT FOR EXHAUST GAS LEAK
If gas is leaking, repair the leak. Replace damaged parts as necessary.