Newbie with an exhaust leak on his '06 Yaris

[ToYarta]

Hi guys,

I have a red 2006 Toyota Yaris 3-Door (82,000 miles and going :cool:) that's been more reliable than Old Faithful- save for an exhaust leak that has recently developed. The tall-tale "tappety-tappety" sound only makes itself heard at idle and low-RPM so it's not THAT irksome of a problem. I'd just rather resolve the issue before it starts to get on my nerves :redface:

So I began to investigate the precise source of this leak only to notice that the bolt attached to the exhaust manifold insulator was missing. Could this possibly cause an exhaust leak or does the problem most likely originate from a leaky exhaust manifold gasket? Refer to this diagram to see which bolt I'm talking about (ref # 91631):

http://www.utoyot8.com/images/433027840/121274300.png

Please note that this diagram belongs to toyotapartszone.com and is not mine :tongue:

[07YarisTypeS]

So are you saying your bolt connecting your exhaust manifold to bracket 25591 is missing? or one of the bolts connecting the manifold to the downpipe is missing? i can tell you that a missing and/or loose bolt on connecting the downpipe and manifold can definately cause a rattle as I have experienced it..

If its the bolt connecting to the 25591 bracket, i mean its possible but i doubt theres an exhaust leak, but maybe just the rattling it does sounds similar?

Wherever you are missing the bolt, im sure thats your problem area..

[WeeYari]

^ OP has identified a heat shield securing bolt to be missing. This will not cause an exhaust leak in the system. It could however be the source of a rattle, which could be described as a "tappety-tappety" sound.

[Vinceb]

since the post says exhaust leak, i'll post this here. seems like the first question was answered already. I've got an exhaust leak or at least that's what it sounds like. Upon acceleration the car sounds like it's spitting (stick your tongue out at somebody and blow, pftt pftt) that's the best sound I can relate it to. it does not happen when cruising on the highway or at idle only when accelerating. The sound is coming from the engine bay.
I talked to a trusted mechanic and he says all the Echo's and Yaris have this problem once they get above 125,000km (I'm at 149,000km) anyway, he said it's where the manifold makes it's first connection to the exhaust under that heat shield in the pic above. He told me it's a tapered doughnut gasket which wears down on one side and when you accelerate it pulls the 2 apart slightly allowing exhaust to escape. the bolts are so horribly rusted they look like they're round so i'm going to let him do the job. Labor and parts (gasket, bolts and springs) $150 or less. anybody else have this issue? Car goes in on tuesday. thanks

[Vinceb]

well took the car in, they got the old rusted bolts and gasket out and the new ones in quite fast. 3/4 hour labour + parts + tax was only 100 bucks, worth it to me and the car sounds like a brand new car again, no more noise.

they changed the gasket labeled #6 in the pic and new bolts and springs as well, # 7 & 8

[Kazimodo]

Thanks to all who posted pictures (drawings ):coolpics:
I have been tolerating this exhaust leak for more than a year now
I will get to it in the coming weeks , lots of loose-nut overnight
and praying to get the rusted nuts out .
..
P.S.
I also see there is another donut in the back ,( # 11 ,with 12 , 13 )
that one moved once in the winter after going thru heavy packed snow
and I got a big leak for 30 seconds but I guess the springs
got the pipes back together and the rear noise never came back.

,,job done , quite easy , bolts came out without any trouble
(thanks to the "loose-nut probably ) , the bolts could even have been reused
but I had new ones so I have a set of spare used ones , the dealer didn't sell
me the springs , said no need to replace , he was right , showed me the new
springs , and my old ones were same length , minus 1/16 inch.

[yuri2002]

well took the car in, they got the old rusted bolts and gasket out and the new ones in quite fast. 3/4 hour labour + parts + tax was only 100 bucks, worth it to me and the car sounds like a brand new car again, no more noise.

they changed the gasket labeled #6 in the pic and new bolts and springs as well, # 7 & 8

I just had #6 donut gasket replaced too. Now it is like a brand new car

[auxmike]

Good thread, I might order me those bits to keep handy....

[tatsimaru]

My girlfriend car have the same problem, how hard is is to change on a 2010 Yaris and where have you baught the part. The dealer ask her 85$ for the part and 200$ in labor.

[suckerface]

My girlfriend car have the same problem, how hard is is to change on a 2010 Yaris and where have you baught the part. The dealer ask her 85$ for the part and 200$ in labor.

For $100 less than that price, you could pick up a brand new header that comes with the donut gasket, and get better performance as a bonus!

http://shop.microimageonline.com/Megan-Racing-stainless-header-Yaris-06-MR-SSH-TY06.htm

[cmac138]

My wife took her 2007 to the stealership for an oil change and they told her she needed a new gasket "between the front and middle exhaust pipes" (I've known about the leak for a while but it never really bothered me). They wanted $1,400 to replace it!!! Looks like I'll be doing it myself this weekend. Thanks

[Kazimodo]

My wife took her 2007 to the stealership for an oil change and they told her she needed a new gasket "between the front and middle exhaust pipes" They wanted $1,400 to replace it!!! Looks like I'll be doing it myself this weekend. Thanks
..
:eyebulge: I think your wife want a fur coat
and was going to pass it on the exhaust bill ,
too bad for her , you have 2 hands , and tools :laugh:

[RG01]

Hey Everyone,
I am so sorry, I do not know how to post a new thread to ask this but, can anyone PLEASE, please, PLEASE help if you are able to with a problem I have had which leaves me locked out of my 2002 Yaris Sedan...basically, the tone that lets you know that you have left your keys in the ignition, (that annoying buzzing sound), has stopped working for a while now and I keep locking my keys in the car. :-( Does anyone have any suggestions for me? I REALLY would greatly appreciate it so very, very much.

[RG01]

:help::cry::confused:Hey Everyone,
I am so sorry, I do not know how to post a new thread to ask this but, can anyone PLEASE, please, PLEASE help if you are able to with a problem I have had which leaves me locked out of my 2002 Yaris Sedan...basically, the tone that lets you know that you have left your keys in the ignition, (that annoying buzzing sound), has stopped working for a while now and I keep locking my keys in the car. :-( Does anyone have any suggestions for me? I REALLY would greatly appreciate it so very, very much.

[RG01]

Sorry bout that I meant to write 2007 toyota yaris.

[CTScott]

For future reference, as you could not have chosen a more off-topic to post under, click on the link below, select the correct area to post under, and then click on the "New Topic" button at the top of the list of threads.

http://www.yarisworld.com/forums/index.php

In regards to the issue, it could be the detection switch on the steering column, the cluster itself, or a fuse.

I would start by checking the MET fuse in the fuse box that is under the bottom of the dash (put your head on the driver's carpet and look up, just behind the hood release lever).

Also, if you don't have the keys in the ignition and just open the car door and turn the headlight on, do you hear the tone?

[auxmike]

Carry an extra on your person. That's what I've been doing for. Years.

[ochy38]

Figured I'd bring up an old post rather than start a new one... I'm in the process of fixing an exhaust leak on my girlfriends '07 3-door. At first, I thought it was just the rear gasket between the cat and muffler that was bad, so I got THIS GASKET (http://shop.advanceautoparts.com/webapp/wcs/stores/servlet/product_x_5781051-P_x_x):
http://www.rockauto.com/getimage/getimage.php?imagekey=121229&imageurl=http%3A//www.rockauto.com/info/Fel-Pro/60668_TOP.jpg
to fix it, and it definitely seems like a totally incorrect part. So now i'm thinking its one of the bigger looking gaskets, the pictures look similar to the donut gaskets for the before-cat connection. I'm now thinking I'll need to replace both, are they the same gasket for the front and rear locations? they look awfully similar.

[auxmike]

Get the dealer parts. I keep both handy. They are white. I think the front one is larger than the rear . Plan on spending about $60 for the pair.

[auxmike]

This is the larger one that goes between the manifold and downpipe...
The real deal, made in JAPAN!

[ochy38]

Thanks for the pictures!

[CKaelin]

Thanks to this thread I was able to quickly diagnose the problem with my exhaust. I started hearing the leak and brought it in to get checked out before looking on Yarisworld. The mechanic had it up on the lift and we decided it was coming from near the manifold. He told me it was so small not to worry until it got worse. I came home and searched on here. Took it back and explained what I had found out in this thread. "Good Research" is what he told me. "The gasket was completely shot." Thanks guys! He replaced the gasket and bolt set. $126 later it's fixed. =)

[Bluecar]

I think my car has the symptoms of a worn-out front gasket. The exhaust note is deeper and louder under acceleration, but still very quiet and placid at idle and steady speeds.

Has anyone changed the gasket themselves? Would you mind sharing your experiences? I'm debating whether to take this on as a DIY job (i.e. trying to weigh up whether any savings in dealer labour will outweigh what I could end up paying my chiropractor!!)

Thank you all!

Car = '07 Yaris 5-dr, auto, 62,000km

[WeeYari]

Easy change with front of car lifted. Everything is easily accessible from underneath. Remove 2 spring bolts from flange and the pipes pull away allowing plenty of room to remove remnants of old and slip in the new.

[Kazimodo]

Make sure the noise comes from the front ,
it could also come from the second donut (gasket ) located around the
right rear passenger's feet , it may also not be a gasket , I had a
noise and changed the rear gasket only to find out it was not that ,
there were 2 holes under some welded plate
on the rear part of the pipe , no big deal , just remove the rubber rings
and take rear pipe with muffler ,with you and work on it while it is
in a vise . see my other thread on this .
http://www.yarisworld.com/forums/showthread.php?t=45670
.
If it is the front donut , i suggest putting some loose-nut on the 2 bolts
with springs the night before ,you attack the project the next day , this way
you won't break the bolts , I didn't put loose nut in the back and
broke a bolt , = extra work .

[Lemayilleur]

Going to go ahead and revive this old thread. Might as well keep all the info in the same spot...

My wife's 2007 Yaris hatch 1.5 exhaust has been "leaky" for over 2 years. It started off has a light "whistle" that was only noticeable during take off. It got worst in the past month until it became "straight-pipe-loud" 2 days ago. I thought it was the header / exhaust manifold, but not quite...

I've looked at it today and there's not a piece of gasket left between the manifold and mid pipe (cat). 1 spring was missing, and the other one was hanging onto the bolt - I took it off by hand... It looks like the bolt got so rust out that the springs managed to pass over the bolts head. But the bolts are still keeping the mid pipe from falling off.

These bolts are rust-welded in place. I tried vice-grips but it didn't move, and I barely have any room to work. I obviously have to break/cut/drill out the old bolts. But I'd really like to do so without taking the header off the motor as I am worried I'll open another can of rusty worms there...

What would you guys suggest.

Picture attached. Bonus picture of the bolts/spring for future reference.

[auxmike]

Wow, I've never seen that before!
How many miles or km on the engine?

[CTScott]

Yikes! I have an extra exhaust manifold, if you want to have one on hand before you try to fight those off.

[auxmike]

Scott, have you ever seen those bolts that corroded?

[Lemayilleur]

170,000km. They salt the road like crazy here.

You should see my 99 Tercel...:cry:

[CTScott]

Scott, have you ever seen those bolts that corroded?

No. Those are crazy.

[auxmike]

105,633mi.
Im at 82k and suspect mind might just be starting to leak...
This winter was brutal in NY and lots of salt here too..

[Lemayilleur]

It wasn't to bad. We put some shielding in there and used a torch to heat em up. Came right off using one of these socket that act as a drill/mesh the strong you torque. :headbang:

[WeeYari]

My wife's 2007 Yaris hatch 1.5 exhaust has been "leaky" for over 2 years. It started off has a light "whistle" that was only noticeable during take off. It got worst in the past month until it became "straight-pipe-loud" 2 days ago. I thought it was the header / exhaust manifold, but not quite...

These are what mine looked like when I replaced them in 2011 at 143,063 km.

http://www.yarisworld.com/forums/attachment.php?attachmentid=44350&stc=1&d=1320516688

Looks like ignoring the leak for 2 years and you really paid the price with the expedited corrosion caused by the hot exhaust gases. After seeing yours, I'm damn glad I didn't ignore mine for any longer than I did.

[IllusionX]

Oh, mine have a crack near the bend on the axle back...

[Kazimodo]

good to see you got the bolts off without breaking them
just by heating them , did you use a welding torch or
just a small propane bottle ??
.
you must feel like you have a brand new car now
fixing an exhaust problem always makes a big difference .:biggrin:

[tmontague]

wow, some of these bolts are bad. I have assumed my '02 Echo has had an exhaust leak for a while now, it's not that bad but a small tapping sound on acceleration. I plan on changing this in a couple weeks.

Now I'm thinking I should be replacing mine in my'08 Yaris since it has 136,000 km on it. Anyone know what the bolts and gasket cost at the stealership in Ontario? Or is is it possible to get at Crappy Tire?

[auxmike]

Did mine today. This is 7 years/83,000mi of use on the parts. Just used a little shot of liquid wrench on the bolts. I used a 6 point 14mm socket. DON'T use a 12 point, it will hop on the bolt head and then you're in trouble. I used a long 3/8 extension and a 3/8 to 1/2 inch adapter so I could use my cheap 1/2 drive torque wrench to get the leverage needed to break free these tough bolts.
Using a 3/8 ratchet handle probably wont work.
I warmed the car up to get the exhaust flange hot to help get things out easier. I did NOT need a torch or flame. Both bolts cracked free with no snapped parts. I took a large/long screwdriver and carefully pried around the edges of the old doughnut gasket to get it off of the exhaust manifold. Watch not to get any bits in the downpipe!
Not that bad a job IF you have experience around rusty exhaust pipes. Also, I did the whole job lying on my back while the car was on Rhino ramps.
Also, the doughnut in the pic is the old one. Note how it was eroding away where it looks like its threaded. The smooth part below that is what's left of the material that can still seal the exhaust.

[Lemayilleur]

good to see you got the bolts off without breaking them
just by heating them , did you use a welding torch or
just a small propane bottle ??
.
you must feel like you have a brand new car now
fixing an exhaust problem always makes a big difference .:biggrin:

We used (I watch my father in law do that part lol) a Oxygen + Acetylene torch. It turned red in 3 second. It was a little scary cause there's the firewall right there as well as some cabling for the O2 sensor and what not right near that flange.

Indeed! So quite now!

Now I'm thinking I should be replacing mine in my'08 Yaris since it has 136,000 km on it. Anyone know what the bolts and gasket cost at the stealership in Ontario? Or is is it possible to get at Crappy Tire?

Less than 60 bucks for the gasket, 2 bolts and 1 spring (springs are 7$ each) for Toyota Gatineau.

[mimelio]

My doughnut gasket between manifold and pipe was leaking. Local muffler shop (Mavis Tire) for $85 replaced the bolts with springs along with the gasket

[33OH]

What are the part numbers on those bolts/springs?

[JDJanitor]

I know this is an old thread,
I have. 2016 Yaris hb, 1.5. on cold starts, I get a valve tap tap sound, car has 58000 miles. Could this be the donut gasket issue I am hearing? Ot just piston slap/ or loud valves

Sent from my moto x4 using Tapatalk

[tmontague]

likely just the injectors, they are noisey on the 1nz. Unless this is a new noise, then it's likely something different. If it's an exhaust leak then it should be coming from the exhaust and that is easy to check but just going under the car when its running and looking or feeling for exhaust gas

[auxmike]

I know this is an old thread,
I have. 2016 Yaris hb, 1.5. on cold starts, I get a valve tap tap sound, car has 58000 miles. Could this be the donut gasket issue I am hearing? Ot just piston slap/ or loud valves

Sent from my moto x4 using Tapatalk

My 2008 hatch now has 122,000miles. I’m the original owner and change oil every 3,000k miles. On cold winter mornings, my car sounds like an old Mercedes Diesel as I pull out of the driveway! Lots of clattering.
Once warmed up noise stops. Your car is pretty new though.

[JDJanitor]

My 2008 hatch now has 122,000miles. I’m the original owner and change oil every 3,000k miles. On cold winter mornings, my car sounds like an old Mercedes Diesel as I pull out of the driveway! Lots of clattering.

Once warmed up noise stops. Your car is pretty new though.I bought mine last spring with 43000 on it, it was a rental car, unknown oil changes. I have been doing 5k mile oil changes.
I don't know the history of it, but it does not. Burn oil between changes . Just noisy when I start it cold. I like to let it idle a little but before driving off to avoid the ticking


Sent from my moto x4 using Tapatalk

[tmontague]

How cold is cold in the morning? What oil weight are you running?

[JDJanitor]

How cold is cold in the morning? What oil weight are you running?From the teens to low 30's F.
Right now I have Mobil 1 0w30 advance fuel economy. With a fram ultra filter.
Last oil was Pennzoil synthetic 5w30 and one before that was supertech 5w30 synthetic.

I would think that it's not too cold for the oil, even a 10w30 probably would be ok with these temps.

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[IllusionX]

My 2008 hatch now has 122,000miles. I’m the original owner and change oil every 3,000k miles. On cold winter mornings, my car sounds like an old Mercedes Diesel as I pull out of the driveway! Lots of clattering.

Once warmed up noise stops. Your car is pretty new though.Mine sounds about the same. It will still do it if the engine revs to 3000rpm when the cold light just turned off. IMO shouldn't be an issue. It's been like this for as long as I remember, and I own the car 12 years already.

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[JDJanitor]

That's good, it probably is just how these engines sound.
It's not hard to hit 3k rpm on the cold engine. I leave my house and go up a short hill, I would not doubt the engine hits 3k

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[tmontague]

From the teens to low 30's F.
Right now I have Mobil 1 0w30 advance fuel economy. With a fram ultra filter.
Last oil was Pennzoil synthetic 5w30 and one before that was supertech 5w30 synthetic.

I would think that it's not too cold for the oil, even a 10w30 probably would be ok with these temps.

Sent from my moto x4 using Tapatalk

ya you should be fine, the oil can easily withstand those temps due to it's very low pour point