Exhaust Pipe: Service and Repair

EXHAUST PIPE

Components:

Components 4wd:

Components:

Components 4wd:

REMOVAL

CAUTION:
^ Wear protective gloves when removing the exhaust pipe.
^ The exhaust pipe is extremely hot immediately after the engine has stopped.
^ Confirm that the exhaust pipe has cooled down before removing it.

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

2. REMOVE NO.2 ENGINE UNDER COVER

3. REMOVE FRONT FLOOR BRACE CENTER
a. Remove the 4 bolts and floor brace.

4. DISCONNECT HEATED OXYGEN SENSOR (for Sensor 2)
a. Disconnect the sensor from the exhaust pipe.

5. REMOVE FRONT EXHAUST PIPE ASSEMBLY
a. Remove the 4 bolts and 4 nuts.
b. Disconnect the exhaust pipe front ends from the exhaust manifold and remove the 2 gaskets.
c. Remove the 2 bolts, 2 compression springs, exhaust pipe and gasket.

6. REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET SUB-ASSEMBLY
a. Remove the 2 bolts and support bracket.

7. REMOVE TAIL EXHAUST PIPE ASSEMBLY
a. Disconnect the 6 exhaust pipe supports to remove the tail pipe.

DISASSEMBLY

1. REMOVE EXHAUST PIPE DAMPER
a. Remove the 2 bolts and damper.

2. REMOVE TAIL EXHAUST PIPE BAFFLE SUB-ASSEMBLY
a. Using a plastic-faced hammer, uniformly tap off the baffle.

REASSEMBLY

1. INSTALL TAIL EXHAUST PIPE BAFFLE SUB-ASSEMBLY
a. Align the baffle with the protruding part of the tailpipe as shown in the illustration.
b. Using a plastic-faced hammer, uniformly tap in the baffle onto the tailpipe.

2. INSTALL EXHAUST PIPE DAMPER
a. Install the support bracket with the 2 bolts.
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)

INSTALLATION

1. INSTALL TAIL EXHAUST PIPE ASSEMBLY
a. Install the tail pipe to connect the 6 exhaust pipe supports.

2. INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET SUB-ASSEMBLY
a. Install the support bracket with the 2 bolts.
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)

3. INSTALL FRONT EXHAUST PIPE ASSEMBLY
a. Using a vernier caliper, measure the free length of the compression spring.
Minimum length: 38.5 mm (1.516 inch)
If the free length is less than the minimum, replace the compression spring.

b. Install a new gasket to the rear side of the front exhaust pipe.

HINT: Using a plastic-faced hammer, uniformly strike the gasket so that the gasket and front exhaust pipe are properly fit.

NOTICE:
^ Be careful with the installation direction of the gasket.
^ Do not reuse the gaskets.
^ To ensure a proper seal, do not use the tailpipe to force the front gasket onto the exhaust pipe.

c. Install 2 new gaskets and the exhaust pipe front ends to the exhaust manifolds with the 4 bolts and 2 nuts.
Torque: 62 Nm (632 kgf-cm, 46 ft. lbs.)

NOTICE: Do not reuse the gaskets.

d. Install the front exhaust pipe to the tail exhaust pipe with the 2 compression springs and 2 bolts.
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)

4. INSTALL HEATED OXYGEN SENSOR
a. Install the sensor.

5. INSTALL FRONT FLOOR BRACE CENTER
a. Install the floor brace with the 4 bolts.
Torque: 7.4 Nm (75 kgf-cm, 65 inch lbs.)

6. CHECK FOR EXHAUST GAS LEAKS
If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.

7. INSTALL NO.2 ENGINE UNDER COVER
8. PERFORM INITIALIZATION
a. Perform initialization.

NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.