Exhaust Pipe: Service and Repair

EXHAUST PIPE

COMPONENTS (Part 1):

COMPONENTS (Part 2):

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 REAR FLOOR NO. 1 PANEL BRACE
(a) Remove the 4 bolts and panel brace.





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

5. REMOVE FRONT FLOOR COVER CENTER LH (for 4WD)
6. DISCONNECT HEATED OXYGEN SENSOR (for Sensor 2)
(a) Disconnect the sensor from the exhaust pipe.





7. 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.





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





9. REMOVE TAILPIPE ASSEMBLY
(a) Disconnect the 6 exhaust pipe supports to remove the tailpipe.





10. REMOVE TAILPIPE BAFFLE SUB-ASSEMBLY
(a) Using a plastic-faced hammer, uniformly tap off the baffle.

INSTALLATION





1. INSTALL TAILPIPE BAFFLE SUB-ASSEMBLY
(a) Align the cutout of the baffle with the protruding part of the tailpipe as shown in the illustration.
(b) Using a plastic-faced hammer, uniformly tap the baffle onto the tailpipe until the cutout on the bottom of the baffle is aligned with the mark on the bottom of the tailpipe.





2. INSTALL TAILPIPE ASSEMBLY
(a) Connect the 6 exhaust pipe supports to install the tailpipe.





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

4. 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 in.)
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 of the installation direction of the gasket.
^ Do not reuse the gaskets.
^ To ensure a proper seal, do not use the tailpipe to force the gasket onto the front exhaust pipe.





(c) Install 2 new gaskets and the exhaust pipe front ends to the exhaust manifold with the 4 bolts and 2 nuts.
Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf)

NOTICE: Do not reuse the gaskets.

(d) Install the front exhaust pipe to the tail tailpipe with the 2 compression springs and 2 bolts.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)

5. INSTALL HEATED OXYGEN SENSOR (for Sensor 2)
(a) Install the sensor.

6. INSTALL FRONT FLOOR COVER CENTER LH (for 4WD)





7. INSTALL FRONT FLOOR BRACE CENTER
(a) Install the floor brace with the 4 bolts.
Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)





8. INSTALL REAR FLOOR NO. 1 PANEL BRACE
(a) Install the panel brace with the 4 bolts.
Torque: 19 N*m (195 kgf*cm, 14 ft.*lbf)

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

10. INSTALL NO. 2 ENGINE UNDER COVER
11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
12. PERFORM INITIALIZATION
(a) Perform initialization.

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