Exhaust 101?

Discussion in 'Gen 2 Prius Main Forum' started by PriusPaddler, Apr 12, 2025 at 4:31 PM.

  1. PriusPaddler

    PriusPaddler Member

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    Replacing my 2009 catalytic converter. Have to adapt between the new cat assembly and downstream remaining exhaust parts.

    Should the adapter go OUTSIDE both pieces? Or outside on upstream and inside on downstream? Or something else or doesn't it matter?

    Thanks in advance.

    This is the part I bought: EPA Catalytic Converter for 2004 2005 2006 2007 2008 2009 Toyota Prius 1.5L L4 | eBay
     
  2. PriusPaddler

    PriusPaddler Member

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    I will not be able to weld, will be using clamps if that helps.
     
  3. Tombukt2

    Tombukt2 Senior Member

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    What is the adapter You talking about the gasket that round ring What do you mean back at the other end to the cat back because that unbolted in your car? So what happened when we did this is I used my sawzall with a Diablo blade and cut the flange off and then when you put the gasket with the tapered part facing back towards new pipe. Now hold the stuff up and take a look and see if you would just be able to slide your new piece over where you just cut your flange off usually if you cut right at the edge of the flange your new pipe will slide on you'll made up at the manifold. You see it stays in okay You can tighten up the bolts at the exhaust manifold and then come back and undo your clamp and put it over your new pipe start the nuts beat it into the position you wanted in If you have a way to hold the two pieces up like with a 2x4 cut or something like that to where you want it to be then you can tighten up those two nuts on the clamp and it should grab around your pipe okay and then after you drive and see everything is okay and all that you can run it by a muffler shop and then you might not even have to get out of the car Just pull you up on the lift and take the clamp off and do what needs to be done and tack you in place. Least my guy does.
     
  4. Tombukt2

    Tombukt2 Senior Member

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    Looks good The one in my '05 which is not on the road now is the same thing I need to take this pipe out and save it I believe ours put the light out and all that I can't remember but it looks like this one you have here is even better than the one I have in 05 for 89 bucks you can't go wrong I don't have to have one here.
     
  5. Hayslayer

    Hayslayer Member

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    The one you bought is a piece of xxxx. The pipe doesn't even match up to the diameter of the Prius pipe where it's supposed to splice into. You need to cut the OEM a few inches in front of the resonator. The replacement unit should slip snuggly over that cut pipe. The one you bought will be like a 55 gallon drum fitting over a fire hydrant. Learned my lesson on those. Had to take it and the rest of the exhaust to a muffler shop so they could use a hydraulic crimp machine to squeeze the end of the new cat pipe until it was the right diameter to fit. Spend the extra 20 bucks and get the right one.

    The pipe on the new one should neck down for the last 5-6 inches or so, like this one:

    Look up auction number 186197166961
     
    #5 Hayslayer, Apr 12, 2025 at 9:36 PM
    Last edited: Apr 12, 2025 at 9:42 PM
  6. MCCOHENS

    MCCOHENS Member

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    So much crap out there, for a first timer these parts are just wrong. Take it to a shop or return them. Buy a Walker replacement, it will bolt in. Consider buying a new resonator too. Then the slip fit junction will be nice clean metal. The connection to the muffler is bolted with a sealing ring so no worries there. Exhaust work sucks, after doing a few hundred repairs I try to buy as many new pieces as possible to avoid slip fits of old into new. Broken bolts, old rubber hangers and working on my back just aren't fun anymore. I want to fix it once and be done.
     
  7. Tombukt2

    Tombukt2 Senior Member

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    Look man you can just drive the car with it not even connected you'll barely even know that it's not connected I drove around like this for I don't know about a week and an '05 with the same converter assembly or one almost exactly like it that's bigger than the original pipe comes that way for a reason but anyway yeah all that. No problem I mean what you were just going to put this all together if the pipe size was right and put a clamp on it and leave it well I don't ever do that I did that on a Cutlass w25 You know like 40 years ago big mistake leaks rattles nuts coming loose all that nonsense was just a crappy way to go but that's what we did back then hell that was before the exhaust shop and every place had a MIG welder but that's all changed and that's why I run it over there with the thing installed like I have it and if I'm not in any hurry I'd drive it around for a day or two it sounds kind of good I should just straight pipe it right out the back do the right things to the pipe to make it make the right noises and leave it But that'll be quite funny going down the road is the engine cuts off here and there You know all of a sudden you be whipping down the road with that nice exhaust sound and then all the sudden just quiet people be looking like what the hell. But your exhaust shop will quickly make a little piece that goes from the fat thing you bought to the skinnier thing in the car and then he'll swell the skinnier thing in the car a little bit so we can slip the pipe inside of or rather on the outside of the thing you bought That's how exhaust is supposed to go that takes him a whopping 19 minutes or something while you're talking and BSN around under the car.