TECHNICAL INSTRUCTIONS
FOR
SPECIAL SERVICE CAMPAIGN G0Y
MUFFLER INSPECTION / REPLACEMENT
CERTAIN
2006−2008 MY RAV4

The repair quality of covered vehicles is extremely important to Toyota. All dealership technicians performing this
recall are required to successfully complete the most current version of the E-Learning course “Safety Recall and
Service Campaign Essentials”. To ensure that all vehicles have the repair performed correctly; technicians
performing this recall repair are required to currently hold at least one of the following certification levels:

• Certified Technician (Chassis)
• Expert Technician (Chassis)
• Master Technician
• Master Diagnostic Technician
It is the dealership’s responsibility to select technicians with the above certification level or greater to
perform this recall repair. Carefully review your resources, the technician skill level, and ability before
assigning technicians to this repair. It is important to consider technician days off and vacation schedules to
ensure there are properly trained technicians available to perform this repair at all times.

I.

OPERATION FLOW CHART

I.

IDENTIFICATION OF AFFECTED VEHICLES
A. COVERED VIN RANGE
NOTE:
 Check the TIS Vehicle Inquiry System to confirm the VIN is covered in this Special Limited Service
Campaign, and that the campaign has not already been completed prior to dealer shipment or by another
dealer.
 TMS warranty will not reimburse dealers for repairs conducted on vehicles that are not covered or were
completed by another dealer.

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II. PREPARATION
A. TOOLS & EQUIPMENT
 Standard hand tools
 Torque Wrench
 Air Gun/Nozzle
 Protective Work Gloves
 Protective Eyewear
B. Campaign Tool – These tools where provided to the dealership at the start of the campaign.

Exhaust Flange Holding Tool (Color:
Silver)

Hook (Color: Silver)

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C. PARTS
Option 1: When holes are not present
Part Number
04002-37131

Part Description
Insulator Kit, Exhaust Pipe*

Quantity
1

*The kit above includes the following parts:
Part Number
17055-31010
17056-31010
94151-80800

Part Description
Insulator Sub-Assy, Exhaust Pipe, No.1 (Upper)
Insulator Sub-Assy, Exhaust Pipe, No.2 (Lower)
Nut, Flange

Quantity
1
1
4

Option 2: When holes are present
Part Number
04002-32131
04002-37128

Part Description
Pipe Sub-Assy, Exhaust, CTR No.2 (Muffler)
Repair Kit, Exhaust Pipe Exchange*

Quantity
1
1

*The kit above includes the following parts:
Part Number
17451-28040
17451-31012
90901-05020
90901-05026
90501-35037
90501-35035

Part Description
Gasket, Exhaust Pipe (for Front side)
Gasket, Exhaust Pipe (for Rear side)
Bolt (for Front side)
Bolt (for Rear side)
Spring, Compression (for Front side)
Spring, Compression (for Rear side)

Quantity
1
1
2
2
2
2

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D. PARTS ILLUSTRATION
Exhaust Pipe Insulator Kit – Option 1: Holes NOT present

5

Muffler Replacement – Option 2: Holes present

III. BACKGROUND
Toyota has received reports that certain 2006 through 2008 Model Year RAV4 vehicles (equipped with a V6 (2GR)
engine) operated in specific cold climate areas where high amounts of road salt are used (“Cold Climate States”)
may exhibit more-than-normal corrosion to the vehicle’s Center No.2 Exhaust Pipe sub-assembly (muffler). Toyota
investigated these reports and determined that this condition may lead to rust perforation in the muffler. This
condition is unrelated to and separate from normal surface rust which is commonly found on metallic surfaces after
some years of use and/or exposure to the environment.
The following states and the District of Columbia are covered by this campaign and will be known as the “Cold
Climate States” under this campaign. CT, DE, IL, IN, KY, MA, MD, ME, MI, MN, NH, NJ, NY, OH, PA, RI, VA, VT,
WI, and WV.

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IV. COMPONENTS

V. MUFFLER INSPECTION
Allow the exhaust temperature to cool before performing the inspection to prevent
personal injury.
A.

INSPECT THE MUFFLER FOR HOLES
1. ROTATE THE CRANKSHAFT PULLEY TO CLOSE ALL
ENGINE VALVES
a) Turn the steering wheel to the full right position.
b) Remove the 4 clips and rear engine under cover RH
located in the passenger side front wheel well.

c)
d)

Rotate the crank clockwise until the timing mark aligns with
the centerline of the oil pan stud bolt.
Reinstall the rear engine undercover RH with the 4 clips.

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2.

INSTALL THE EXHAUST FLANGE HOLDING TOOL
Proper installation of the Exhaust Flange Holding Tool is critical to prevent excessive
load from being applied to the exhaust gasket and creating an exhaust leak. Follow the
instructions carefully.
a) Install the upper half of the Exhaust Flange Holding Tool
with the stamped “F” oriented toward the front of the
vehicle.
b) Confirm the flange holding tool alignment mark lines up
with the centerline of the flange joint as shown.

c) Confirming the stamped “F” is oriented toward the front of
vehicle.
d) Install the lower half of the tool by inserting the tabs into
the slots located in the upper half of the tool.
e) Looosley tighten the wing nuts by hand.

f) Tighten the wing bolts hand tight.
g) Confirm the tool alignment mark remains aligned with the
centerline as shown.
h) Confirm the flange tool does not touch the flange joint on
the exhaust as shown.
If the flange tool contacts the exhaust flange
you must remove the tool and reinstall.
Note: Clearance between the upper and lower halves
of the tool is acceptable when installed.

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3.

DISCONNECT THE EXHAUST PIPE SUPPORT
a) Disconnect the 2 front muffler exhaust hangers.
Follow the exhaust hanger removal order
exactly to ensure an exhaust leak is not
created!

b) Install the support hooks with the hooks facing outward
from the muffler.
Note: This will ensure that the hooks catch the muffler
supports as the remaining rubber supports are
removed and the exhaust is lowered.

c) Disconnect the rear exhaust pipe assembly hangers in the
order shown.
Note: Removing the exhaust hangers in the order
shown will ensure that minimal stress is placed on the
compression gasket.

d) While securely supporting the exhaust, carefully
disconnect the rear muffler hanger.
Make sure you are holding the pipe securely so
it does not fall!

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e) Slowly lower the exhaust assembly and engage the 2 center No.2 Exhaust pipe hanger hooks.

4. PERFORM MUFFLER ASSEMBLY HOLE INSPECTION



a)

ALWAYS wear protective eyewear.
The inspection will require 2 technicians, one to apply shop air and one to inspect the
muffler assembly.

Visually inspect the Muffler Assembly for holes.


If holes are present refer to the “Inspection Result Table” below.
b)

Using rubber nozzle air gun and a shop rag apply air
pressure to the exhaust system.

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c)

While applying air pressure using the air gun, inspect the muffler assembly as shown for air leaks
indicating a hole is present.

INSPECTION RESULT

ACTION REQUIRED

Holes are Not Present
Holes are Present

Install the NEW Exhaust Pipe Insulator SubAssembly, Option 1 (Refer to Section VI)
Replace the Muffler Assembly, Option 2
(Refer to Section VII)

Make sure to remove the shop cloth from the tail exhaust pipe assembly after the inspection.

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VI. EXHAUST PIPE INSULATOR SUB-ASSEMBLY INSTALLATION (OPTION 1)
A.

INSTALL THE NEW EXHAUST PIPE INSULATOR SUB-ASSEMBLY



To prevent yourself from being burned and protect your hands, wait until the exhaust
pipe is cool and wear protective gloves before beginning the installation.
Remove all debris from muffler to prevent damage when installing the insulator.
1.

LOOSELY INSTALL THE NO. 1 INSULATOR
MUFFLER ASSEMBLY

TO THE

a) Confirm you have the No. 1 Insulator (does not contain
studs).
b) Confirm that the orientation arrow points toward the front
of the vehicle.
c) Rotate the No. 1 Insulator from the center of the vehicle
and place it on top of the muffler assembly.

2.

LOOSELY INSTALL THE NO. 2 INSULATOR
MUFFLER ASSEMBLY

TO THE

a) Confirm that the orientation arrow points toward the front
of the vehicle.
b) Align the studs with the holes on the flanges of the upper
insulator and loosely secure with the 4 nuts provided by
hand.
Do not tighten the nuts prior to adjusting
the insulator to ensure no rattles are
created.
3.

Perform Final Insulator Alignment
a) Visully check all contact surfaces of the No. 1 Insulator and No. 2 Insulator to confirm that no mesh is
caught/folded between them. If caught/folded carefully use a screw driver to adjust the mesh until it is
in the “OK” condition.

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b) Push the insulator assembly toward the rear of the vehicle until the mesh from the No.2 Insulator
contacts the muffler.

Failure to firmly install the insulator securley against the muffler will results in
noise/vibration.
4.

TORQUE THE INSULATOR NUTS
a) Tigten the 4 nuts until the upper and lower insulator
flanges touch.
Torque Spec: 14 ft.lbf (19 Nm or 194 kgf)

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B.

RECONNECT THE EXHAUST PIPE HANGERS
1.

RECONNECT THE REAR MUFFLER EXHAUST
HANGER
a) Using your hands to support the exhaust pipe at the
rear of the muffler, attach the rear muffler exhaust
hanger.

2.

RECONNECT THE TAIL EXHAUST PIPE HANGERS
a) Lift the tail exhaust pipe and reconnect the forward
most tail pipe hanger.
b) Proceed with reconnecting the rear tail pipe hanger.

3.

RECONNECT THE FRONT MUFFLER HANGERS

4.

REMOVE THE FLANGE HOLDING TOOL

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◄ VERIFY REPAIR QUALITY ►
−
−
−
−
−

Confirm ALL Rubber Exhaust Hangers are removed and installed EXACTLY as described in
these instructions.
Confirm the Support Hooks used with the flange tool have been removed.
Confirm ALL inspection steps are followed EXACTLY as described in these instructions.
Confirm there are no exhaust leaks from flange gaskets.
Confirm there are no exhuast rattles/noises.

If you have any questions regarding this Limited Service Campaign, please contact your regional representative.

VII. MUFFLER ASSEMBLY REPLACEMENT (OPTION 2)
A.

REMOVE THE MUFFLER ASSEMBLY
1.

REMOVE THE FLANGE HOLDING TOOL

2.

REMOVE THE TAIL EXHAUST PIPE ASSEMBLY
a) Support the tail pipe so it will not fall during the
removal.
b) Remove the 2 bolts and and 2 compression springs.
c) Remove tail pipe assembly.

3.

REMOVE THE MUFFLER ASSEMBLY
a) Support the muffler assembly so it will not fall during
removal.
b) Remove the 2 bolts and compression springs.
c) Remove the muffler assembly.
d) Remove the Support Hooks.
e) Remove the 2 exhaust pipe gasket from the muffler
and header pipe.

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B.

INSTALL THE NEW MUFFLER ASSEMBLY
1.

INSTALL THE NEW EXHAUST PIPE GASKETS
a) Install the new exhaust pipe gaskets by hand.



Front of Muffler Gasket: P/N 17451-28040
Thickness: 14.6 mm (.575 in.)
Mark Color: Black
Rear Muffler Gasket: P/N 17451-31012
Thickness: 10.9 mm (.429 in)
Mark Color: Yellow

Note:
 Confirm you use the correct gasket, they vary
in thickness.
 If you cannot fully seat the gasket by hand use
a wood block to press it on.
 Do not use a hammer as this can damage the
gasket.
2.

CONNECT THE MUFFLER EXHAUST HANGERS
a) Connect the 3 muffler hangers to the new muffler
assembly.
Note: 2 technicians may be used for this step if
needed.

3.

CONNECT THE MUFFLER ASSEMBLY TO THE
CENTER PIPE
a) Connect the Muffler Assembly to the Center Pipe with
the 2 NEW Compression Springs and 2 NEW bolts.



Bolt P/N: 90901-05020
Color: Silver
Length: 75 mm (2.95 in)
Compression Spring P/N: 90501-35037
Color: Blue
Length: 43 mm (1.69 in)

Torque Spec: 32 ft. lbf (43 Nm, 440 kgf cm)
4.

REINSTALL THE TAIL EXHAUST PIPE
a) Reconnect the tail pipe to the 2 exhaust hangers.
Note: 2 technicians may be used for this step if
needed.

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5.

CONNECT THE MUFFLER ASSEMBLY TO THE TAIL
PIPE
a) Reinstall the tail pipe to the muffler assembly using the
2 New compression springs and 2 NEW bolts.



Bolt P/N: 90901-05026
Color: Black
Length: 74 mm (2.91 in)
Compression Spring P/N: 90501-35035
Color: Pink
Length: 40 mm (1.57 in)

Torque Spec: 32 ft. *lbf (43 Nm, 440 kgf* cm)

◄ VERIFY REPAIR QUALITY ►
−
−
−
−
−

Confirm ALL Rubber Exhaust Hangers are removed and installed EXACTLY as described in
these instructions.
Confirm the Support Hooks used with the flange tool have been removed.
Confirm ALL inspection steps are followed EXACTLY as described in these instructions.
Confirm there are no exhaust leaks from flange gaskets.
Confirm there are no exhuast rattles/noises.

If you have any questions regarding this Limited Service Campaign, please contact your regional representative.

I. APPENDIX
A. PARTS DISPOSAL
As required by Federal Regulations, please make sure all recalled parts (original parts)
removed from the vehicle are disposed of in a manner in which they will not be reused,
unless requested for parts recovery return.
B. CAMPAIGN DESIGNATION DECORDER

Examples:
A0D = Launched in 2010, Remedy Phase, 4th Campaign Launched in 2010
B1E = Launched in 2011, Interim Phase, 5th Campaign Launched in 2011
C1C = Launched in 2012, Interim Phase, 3rd Campaign Launched in 2012

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