2002 Lexus ES 300FACTORY OEM SERVICE PROCEDURE

Replacement (2AZ-FE)

WARNING: This page is about a different car, the 2004 Toyota Camry Solara. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Check if an old gasket still remains on the pipe. If so, remove it. Also, check if any bolts or nuts are rusted. If so, replace them.
  1. REMOVE FLOOR PANEL BRACE REAR 
    1. Remove the 2 bolts and panel brace.
  2. REMOVE EXHAUST PIPE DAMPER (A/T) 
    1. Remove the 2 bolts and damper.
  3. REMOVE EXHAUST PIPE ASSY CENTER 
    1. Remove the 2 bolts, 2 nuts and pipe center from the exhaust pipe front.
    2. Remove the 2 nuts and pipe center from the exhaust pipe tail.
    3. Remove the pipe center from the 2 exhaust pipe supports.
  4. REMOVE HEATED OXYGEN SENSOR 
    1. Disconnect the heated oxygen sensor (bank 1 sensor 2) connector.
    2. Remove the heated oxygen sensor (bank 1 sensor 2).
  5. REMOVE FRONT EXHAUST PIPE NO. 1 SUPPORT BRACKET 
    1. Remove the 2 nuts and front support bracket.
  6. REMOVE REAR EXHAUST PIPE NO. 1 SUPPORT BRACKET 
    1. Remove the 2 bolts and rear support bracket.
  7. REMOVE EXHAUST PIPE ASSY FRONT 
    1. Remove the 2 nuts and pipe front.
  8. REMOVE EXHAUST PIPE ASSY TAIL 
    1. Remove the pipe tail from the 3 exhaust pipe supports.
  9. REMOVE TAIL PIPE BAFFLE 
    1. Using a plastic hammer, tap the baffle uniformly to remove it.
    Fig 1: Removing Tail Pipe Baffle
    G02853887Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL TAIL PIPE BAFFLE 
    1. Align the keyway of the baffle with the key location on the pipe.
    2. Using a plastic hammer, tap the baffle to install it.
    Fig 2: Installing Tail Pipe Baffle
    G02853888Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL EXHAUST PIPE ASSY TAIL 
    1. Install the pipe with the 3 exhaust pipe supports.
  12. INSTALL EXHAUST PIPE ASSY FRONT 
    1. Install a new gasket and the pipe front to the exhaust manifold converter with the 2 nuts.

      Torque:  62 N.m (632 kgf.cm, 46 ft.lbf)

  13. INSTALL REAR EXHAUST PIPE NO. 1 SUPPORT BRACKET 
    1. Install the rear support bracket with the 2 bolts.

      Torque:  33 N.m (337 kgf.cm, 24 ft.lbf)

    Fig 3: Installing Rear Support Bracket
    G02853889Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.