Exhaust System: Service and Repair

EXHAUST SYSTEM REMOVAL/INSTALLATION [L3 WITH TC]

WARNING:
- A hot engine and exhaust system can cause severe burns. Turn off the engine and wait until they are cool before removing the exhaust system.

1. Remove the battery cover. Removal and Replacement

2. Disconnect the negative battery cable.

3. Remove the charge air cooler. (See Service and Repair)

4. Remove in the order indicated in the table.

5. Install in the reverse order of removal.










TWC Removal Note

1. Disconnect the hanger rubber except for the one installed to the rear end of the vehicle from the silencer, and suspend the silencer using rope.






2. Remove the TWC.

Seal Ring Removal Note

1. Remove the seal ring using a flathead screwdriver being careful not to damage the pipe.






A/F Sensor, HO2S Removal Note

1. Remove the A/F sensor or HO2S using the SST before removing the exhaust manifold.






Silencer Removal Note

1. Remove the rear shock absorber lower bolts. Removal and Replacement

2. Loosen the rear crossmember component installation bolts (6 locations) and lower the rear crossmember component approx. 70 mm {2.8 in}. Service and Repair

3. Remove the main silencer.

Exhaust Manifold Insulator (Upper) Removal Note

1. Remove the charge air cooler bracket.

2. Remove the exhaust manifold insulator (upper)

Exhaust Manifold Installation Note

1. Tighten the exhaust manifold installation nuts in the order shown.

Tightening torque
- 43-64 Nm {4.4-6.5 kgf-m, 32-47 ft-lbf}






WU-TWC Installation Note

1. Temporarily tighten No.1 shown in the figure.






2. Temporarily tighten No.2 shown in the figure.

3. Temporarily tighten No.3 shown in the figure.

4. Completely tighten No.1 shown in the figure.

Tightening torque
- 38-51 Nm {3.9-5.2 kgf-m, 29-37 ft-lbf}

5. Completely tighten No.2 shown in the figure.

Tightening torque
- 38-51 Nm {3.9-5.2 kgf-m, 29-37 ft-lbf}

6. Completely tighten No.3 shown in the figure.

Tightening torque
- 38-51 Nm {3.9-5.2 kgf-m, 29-37 ft-lbf}

Silencer Installation Note

1. Spray carbon remover (TB6601 or equivalent) on the flared section of the exhaust pipe.






2. Remove the carbon adhering to the flared section shown in the figure using a nylon brush or sandpaper (No. 400 or equivalent).

Seal Ring (WU-TWC Side) Installation Note

CAUTION:
- If installation is performed without using the SST, the seal ring will be damaged and deformed, resulting in an incorrect installation. Always use the SST to install the seal ring.

1. Temporarily install the seal ring to the pipe so that the seal ring is even with the flange.






2. Install the SST to the seal ring so that the SST is even with the flange.






3. Press in the seal ring by tapping the SST using a plastic hammer until the seal ring contacts the flange.






Seal Ring (TWC Side) Installation Note

CAUTION:
- If installation is performed without using the SST, the seal ring will be damaged and deformed, resulting in an incorrect installation. Always use the SST to install the seal ring.

1. Temporarily install the seal ring to the pipe so that the seal ring is even with the flange.






2. Install the SST to the seal ring so that the SST is even with the flange.






3. Press in the seal ring by tapping the SST using a plastic hammer until the seal ring contacts the flange.






TWC Installation Note

1. Spray carbon remover (TB6601 or equivalent) on the flared section of the exhaust pipe.






2. Remove the carbon adhering to the flared section shown in the figure using a nylon brush or sandpaper (No. 400 or equivalent).