2002 Lexus ES 300FACTORY OEM SERVICE PROCEDURE

Replacement (3MZ-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 HEATED OXYGEN SENSOR 
    1. Disconnect the 2 heated oxygen sensor (bank 1, 2 sensor 2) connectors.
    2. Remove the 2 heated oxygen sensors (bank 1, 2 sensor 2).
  2. REMOVE FRONT EXHAUST PIPE NO. 1 SUPPORT BRACKET 
    1. Remove the 2 nuts and front support bracket.
  3. REMOVE FLOOR PANEL BRACE REAR 
    1. Remove the 2 bolts and brace.
  4. REMOVE REAR EXHAUST PIPE NO. 1 SUPPORT BRACKET 
    1. Remove the 2 bolts and rear support bracket.
  5. REMOVE EXHAUST PIPE ASSY FRONT 
    1. Remove the 2 nuts holding the exhaust manifold converter No. 2 to the pipe front.
    2. Remove the 2 bolts holding the exhaust manifold converter RH to the pipe front.
    3. Remove the 2 bolts and 2 nuts holding the exhaust pipe center to the pipe front. Then remove the pipe front.
  6. REMOVE EXHAUST PIPE ASSY CENTER 
    1. Remove the 2 nuts from the pipe tail.
    2. Remove the pipe center from the 2 exhaust pipe supports.
    3. Remove the gasket between the pipe center and pipe tail.
  7. REMOVE EXHAUST PIPE ASSY TAIL 
    1. Remove the pipe tail from the 3 exhaust pipe supports.
  8. REMOVE TAIL PIPE BAFFLE 
    1. Using a plastic hammer, tap the baffle uniformly to remove it.
    Fig 1: Removing Tail Pipe Baffle
    G02853892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL TAIL PIPE BAFFLE 
    1. Align the keyway of the baffle with the key location on the pipe assy tail.
    2. Using a plastic hammer, tap the baffle to install it.
    Fig 2: Installing Tail Pipe Baffle
    G02853893Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL EXHAUST PIPE ASSY TAIL 
    1. Install the pipe tail with the 3 exhaust pipe supports.
  11. INSTALL EXHAUST PIPE ASSY CENTER 
    1. Install a new gasket between the pipe center and pipe tail.
    2. Install the exhaust pipe center to the 2 exhaust pipe supports.
    3. Install the pipe center with the 2 nuts.

      Torque:  56 N.m (571 kgf.cm, 41 ft.lbf)

  12. INSTALL EXHAUST PIPE ASSY FRONT 
    1. Install the 3 new gaskets to the pipe front.
    2. Install the pipe front to the exhaust manifold converter RH with the 2 bolts.

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

    3. Install the pipe front to the exhaust manifold converter No. 2 with the 2 nuts.

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

    4. Install the pipe front to the pipe center with the 2 bolts and 2 nuts.

      Torque:  56 N.m (571 kgf.cm, 41 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
    G02853894Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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Return to Chapter: Section 249 (Engine Exhaust Assembly)
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • 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.