Exhaust Pipe: Service and Repair

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





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

3. DISCONNECT HEATED OXYGEN SENSOR (for 2WD)





(a) Remove the grommets of the heated oxygen sensors (BANK 1, BANK 2).





(b) Using the SST remove a oxygen sensors (BANK 1, BANK 2).
SST 09224-00010

4. DISCONNECT HEATED OXYGEN SENSOR (for 4WD)





(a) Remove the grommets of the heated oxygen sensors (BANK 1, BANK 2) and 2 clips.





(b) Using the SST remove the heated oxygen sensors (BANK 1, BANK 2).
SST 09224-00010

5. REMOVE FRONT EXHAUST PIPE ASSEMBLY





(a) Remove the 4 bolts and 4 nuts.





(b) Remove the 2 bolts and 2 compression springs from the tail exhaust pipe assembly.
(c) Remove the front exhaust pipe assembly and 3 gaskets.





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





7. REMOVE EXHAUST PIPE DAMPER
(a) Remove the 2 bolts and exhaust pipe damper.





8. REMOVE TAIL EXHAUST PIPE BAFFLE SUB-ASSEMBLY
(a) Using a plastic hammer uniformly tap off the exhaust pipe baffle sub-assemblies.

INSTALLATION

1. INSTALL TAIL EXHAUST PIPE BAFFLE SUB-ASSEMBLY
(a) Align the baffle with the protruding part of the tail exhaust pipe assembly as shown in the illustration.





(b) Using a plastic hammer uniformly tap the baffle sub-assemblies onto the tail exhaust pipe assembly.





2. INSTALL EXHAUST PIPE DAMPER
(a) Install the exhaust pipe damper with the 2 bolts.
Torque: 19 Nm (194 kgf-cm, 14 ft.-lbf)





3. INSTALL TAIL EXHAUST PIPE ASSEMBLY
(a) Install the tail exhaust pipe assembly with the 6 exhaust pipe supports.

4. INSTALL FRONT EXHAUST PIPE ASSEMBLY





(a) Using a vernier caliper measure the free length of the compression springs.
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 end of the front exhaust pipe.

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

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

(c) Install 3 new gaskets and front exhaust pipe assembly.

CAUTION: Do not reuse the gaskets.





(d) Install the 2 bolts and 2 compression springs.
Torque: 43 Nm (438 kgf-cm, 32 ft.-lbf)





(e) Install 4 new nuts and 4 bolts.
Torque: 39 Nm (398 kgf-cm, 29 ft.-lbf)

NOTICE: Do not reuse the nuts.

5. INSTALL HEATED OXYGEN SENSOR (for 2WD)





(a) Before installing the heated oxygen sensors twist the sensor wires counterclockwise 4 turns.





(b) Using the SST install the heated oxygen sensors to the front exhaust pipe.
SST 09224-00010
Torque: 44 Nm (449 kgf-cm, 33 ft.-lbf)

(c) After installing the sensors check that the sensor wires are not twisted.
If the sensor wires are twisted reinstall them.





(d) Install the grommets of the heated oxygen sensors.

6. INSTALL HEATED OXYGEN SENSOR (for 4WD)





(a) Before installing the sensors twist the sensor wires counterclockwise 4 turns.





(b) Using the SST install the heated oxygen sensors tc the front exhaust pipe.
SST 09224-00010
Torque: 44 Nm (449 kgf-cm, 33 ft.-lbf)

(c) After installing the sensors check that sensor wires are not twisted.
If the sensor wires are twisted reinstall them.





(d) Install the grommets of heated oxygen sensors.





7. INSTALL FRONT CENTER FLOOR BRACE
(a) Install the front center floor brace with the 4 bolts.
Torque: 7.4 Nm (75 kgf-cm, 65 in.-lbf)





8. INSTALL REAR NO.1 FLOOR PANEL BRACE
(a) Install the rear No.1 floor panel brace with the 4 bolts.
Torque: 19 Nm (194 kgf-cm, 14 ft.-lbf)

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