Exhaust Leak

[zerosl]

So I have an 08 but can't figure out where to start with this exhaust leak.

It is likely near the exhaust headers or downpipe as exhaust smell comes into the cabin if i have my HVAC to vent from outside.

Any suggestions for techniques or places to start looking?

Thanks

[WeeYari]

With 99% certainty, it is the donut gasket between the header and the down pipe. An '08 is past due for replacement if still on the original Open the hood, start the car, and reach into that area with an open hand. You should be able to feel the gases puffing against your fingers.

This is what the gasket in my '06 looked like in November 2011. I am once again due for a replacement.

https://uploads.tapatalk-cdn.com/20171017/388a4c62e4f6e1ee0bd789f520941ca5.jpg

Sent from my Elite_5_5_Octa using Tapatalk

[06YarisRS]

^ +1 My money's on WeeYari's diagnosis. Mine was gone, but so was the entire flange. The cat pipe had completely separated from the manifold and was hanging down about 1/4".

[zerosl]

do you have any part numbers?

[WeeYari]

Toyota OE part numbers;

Gasket 17451-21070
Bolts 90080-10291

They are not what one would consider cheap.

Sent from my Elite_5_5_Octa using Tapatalk

[06YarisRS]

https://www.ebay.com/itm/Exhaust-Pipe-Flange-Gasket-Fel-Pro-61502-fits-06-13-Toyota-Yaris-1-5L-L4/322404051188?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649

This is the one I bought.

[govtec]

How hard is this job to do it myself and what are the steps involved to change out the gaskets and bolts? Thanks

[IllusionX]

How hard is this job to do it myself and what are the steps involved to change out the gaskets and bolts? ThanksIf you live in salt belt. The bolt is likely rusted, and you will need to heat the bolt till red to take it out. It's not a job to crawl under to do.

Sent from my SM-G930W8 using Tapatalk

[govtec]

Ok, I might just take it to Midas.

[06YarisRS]

Ok, I might just take it to Midas.

That's probably the best thing to do because they do tend to rust badly with moisture and continual heating/cooling cycles. That said I have removed pretty rusty ones by soaking them a few times with ReleasAll or similar and used my electric impact gun. I can't see a muffler shop charging much at all to replace that donut.

[IllusionX]

That's probably the best thing to do because they do tend to rust badly with moisture and continual heating/cooling cycles. That said I have removed pretty rusty ones by soaking them a few times with ReleasAll or similar and used my electric impact gun. I can't see a muffler shop charging much at all to replace that donut.It was a good 20mins job.

Sent from my SM-G930W8 using Tapatalk

[zerosl]

Ordered the parts from RockAuto

Order Parts List:
EASTERN EXHAUST EE4979 Springs
EASTERN EXHAUST EE4978 Bolts
FEL-PRO 61502 {#1745121070} Flange Donut Gasket

Parts should arrive friday and will tackle on saturday

I have access to a four post lift and will hopefully will tackle this quickly

[xdarkxfirex]

I had the same problem, no leak, but a noise and couldnt figure out where it was coming from. Turned out to be this flange gasket. Toyota wanted almost $50 for it and I got it from a local parts shop aftermarket for $8. Had to sand it a little to get a perfect fit. After that it was fine. Reused same bolts and put antiseize on threads.

[zerosl]

well, I started on this job and the bolts were so corroded that they both snapped.

I may well call it a day

[zerosl]

I was able to cut away the bolts between the flanges, but will need a longer drill. I replaced the donut gasket and clamped it shut with a U bolt until I come back to it after purchasing the correct parts

Noise is gone, but now I have a P0031 fault code.

I wonder if I damaged the O2 sensor while messing around?

nightmare fuel

[06YarisRS]

I wonder if I damaged the O2 sensor while messing around?

Maybe the wiring which is not far from the flange. Could you have nicked a wire with your drill bit? The downstream sensor has 4 wires. Not sure about the upstream wideband sensor.

[zerosl]

yea, its possible, I'll start checking the part once I have a free cycle

[zerosl]

So I'm guessing my P0031 corresponds to bank 1 sensor 1 which is the upstream.
The more difficult one, should I go from the top or bottom?

decided to use two of these flange repair
https://www.autozone.com/emission-control-and-exhaust/exhaust-flange-kit/walker-exhaust-flange-kit/277182_0_17365

[zerosl]

Flange repair was too small, if anyone else decides to go this route, I recommend getting a slightly bigger size

[zerosl]

Walker 31871
or any other flange repair kit that is about 2 1/4 inch
They run about 15 bucks for two from rockauto

Good luck to anyone who needs to do this, hopefully this helps at all

[grilled cheeseus]

Just replaced the original gasket on my 2007 hatchback with 120k miles and 10 salty upstate NY winters. :D

Photos (https://imgur.com/a/QfNKn)

Before trying to loosen the flange bolts, I used a MAP-Pro torch ($50 at the Homeless Despot) to get the nuts red-hot. You can hit the nuts with a torch from the engine bay -- I unclipped a wiring harness to make more room to work. Watch your aim -- there are O2 sensor wires just above the flange on the driver's side.

After heating each nut, I crawled underneath, hammered a socket with long extension onto the rusty bolt head, and carefully(!) applied torque. Got them both loose with no fuss, and the rest of the job was easy. I used new bolts but kept the original captive nuts.

The replacement gasket I used was a Walker 31619. May be a little different than OEM gasket size (definitely different material), but it seems to make a good seal. Car sounds much quieter now and less rough when accelerating. I'm probably breathing cleaner cabin air too.

[ezhacker1]

Time to do mine as well. I can taste the fumes with the hood open.. and a shot of SeaFoam shows it's leaking there, also be a good idea to take the header off and check that as well. Good info on the or replacements.

[zerosl]

Yes, I would definitely monitor this in the future and for anyone else who owns this vehicle.

My spring bolts were just corroded to pieces which is why they snapped so quickly.

But yes, Definitely torch/Heat before torquing anything exhaust in the future!

[hodginsa]

I've got to do this soon. Winter is here and heating the car with re-circulation on just fogs the windows bad. Driving with it off the car just fills up with fumes.

Good to know its likely just the gasket. I haven't investigated yet though.

[Mike Dexter]

I was able to cut away the bolts between the flanges, but will need a longer drill. I replaced the donut gasket and clamped it shut with a U bolt until I come back to it after purchasing the correct parts


Same thing happened to me. I was able to helicoil it by using an adapter to hold the bit/tap/helicoil tool to a 12" extension bar.

[myfirstyota]

Before trying to loosen the flange bolts, I used a MAP-Pro torch ($50 at the Homeless Despot) to get the nuts red-hot. You can hit the nuts with a torch from the engine bay -- I unclipped a wiring harness to make more room to work. Watch your aim -- there are O2 sensor wires just above the flange on the driver's side.

After heating each nut, I crawled underneath, hammered a socket with long extension onto the rusty bolt head, and carefully(!) applied torque.

Has never failed me. I've done 3 of these gaskets now. Gasket from Toyota (canada) $50-60, I think the bolts are $7 and change each.

[dogsridewith]

This spring-bolt joint is special. Circa 1990 Corolla and Tercel used a down pipe w/ a flex section, so all stock exhaust connections were flanged. On all of these I used 3/8 stainless nuts and bolts from the hardware store...no more rusty stuck fasteners next time a pipe or muffler was replaced.

[DarkShadowFox]

flex seal

[dogsridewith]

Isn't "flex seal" polyurethane glue and caulk sold on TV? (Guy cuts a boat in half, glues it together and zooms across the lake.)