Exhaust Pipe: Service and Repair

Part 1 Of 2:

Part 2 Of 2:

EXHAUST PIPE ASSY
Removal & Installation and Disassembly & Reassembly





1. REMOVE ENGINE UNDER COVER ASSY (W/ ENGINE UNDER COVER ASSY)
a. Remove the 5 clips, 4 bolts and 2 screws, and then remove the engine under cover.
2. REMOVE ENGINE UNDER COVER NO.1





a. w/o Engine Under Cover
1. Remove the 2 clips, 6 bolts and 2 screws, and then remove the engine under cover No. 1.





b. w/ Engine Under Cover
1. Remove the 2 clips, 2 bolts and 2 screws, and then remove the engine under cover No. 1.





3. REMOVE ENGINE UNDER COVER NO.2 (W/ ENGINE UNDER COVER NO.2)
a. Remove the 2 bolts.
b. Slide the engine under cover No. 2 toward the rear to detach it from the retainers, and then remove the engine under cover No. 2.
4. REMOVE HEATED OXYGEN SENSOR





a. Bank 1 Sensor 2
1. Disconnect the heated oxygen sensor connector.
2. Remove the connector clamp.
3. Remove the 2 wire harness clamps.
4. Remove the heated oxygen sensor.





b. Bank 2 Sensor 2
1. Disconnect the heated oxygen sensor connector.
2. Remove the wire harness clamp.
3. Remove the heated oxygen sensor.





5. REMOVE EXHAUST PIPE ASSY TAIL
a. Remove the 2 bolts and 2 compression springs.
b. Remove the exhaust pipe tail from the exhaust pipe support.
c. Remove the gasket from the exhaust pipe center.





6. REMOVE EXHAUST TAIL PIPE BAFFLE SUB ASSY
a. Using a plastic hammer, tap the exhaust tail pipe baffle uniformly to remove.





7. REMOVE EXHAUST PIPE ASSY CENTER
a. Remove the 2 bolts and 2 compression springs.
b. Remove the exhaust pipe center from the 4 exhaust pipe supports.
c. Remove the gasket from the exhaust pipe front No. 3.





8. REMOVE EXHAUST PIPE SUB-ASSY FRONT NO.3
a. Remove the 2 bolts and 2 nuts, and remove the exhaust pipe front No. 3 and the 2 gaskets.





9. REMOVE EXHAUST PIPE ASSY FRONT
a. Remove the 2 nuts.
b. Loosen the clamp bolts, and remove the exhaust pipe front and the gasket.





10. INSTALL EXHAUST PIPE ASSY FRONT
a. Install a new gasket and the exhaust pipe front to the exhaust pipe support bracket No. 1.

NOTICE: When installing the exhaust pipe front, align gaps of the clamp and the exhaust pipe support bracket No. 1.

b. Tighten 2 new nuts.
Torque: 56 Nm (571 kgf-cm, 41 ft. lbs.)
c. Tighten the clamp bolt.
Torque: 21 Nm (214 kgf-cm, 16 ft. lbs.)
11. INSTALL EXHAUST PIPE SUB-ASSY FRONT NO.3
a. Install 2 new gaskets and the exhaust pipe front No. 3 with the 2 bolts and 2 new nuts.
Torque: 56 Nm (571 kgf-cm, 41 ft. lbs.)





12. INSTALL EXHAUST PIPE ASSY CENTER
a. Compression spring inspection
1. Using vernier calipers, measure the free length of the compression spring.
Minimum length: 41.5 mm (1.634 inch) if the free length is less than minimum, replace the compression spring.





b. Install a new gasket to the exhaust pipe front No. 3 as shown in the illustration.
c. Tighten the 2 bolts and 2 compression springs.
Torque: 48 Nm (490 kgf-cm, 35 ft. lbs.)





13. INSTALL EXHAUST TAIL PIPE BAFFLE SUB ASSY
a. Align the keyway of the exhaust tail pipe baffle with the key located on the exhaust pipe tail.
b. Using a plastic hammer, tap the exhaust tail pipe baffle to install.
14. INSTALL EXHAUST PIPE ASSY TAIL





a. Compression spring inspection
1. Using vernier calipers, measure the free length of the compression spring.
Minimum length: 40.5 mm (1.594 inch)
If the free length is less than minimum, replace the compression spring.





b. Install a new gasket to the exhaust pipe center as shown in the illustration.
c. Tighten the 2 bolts and 2 compression springs.
Torque: 48 Nm (490 kgf-cm, 35 ft. lbs.)
15. INSTALL HEATED OXYGEN SENSOR
Torque: 44 Nm (449 kgf-cm, 33 ft. lbs.)
16. CHECK FOR EXHAUST GAS LEAKS
17. INSTALL ENGINE UNDER COVER NO.2 (W/ ENGINE UNDER COVER NO.2)
18. INSTALL ENGINE UNDER COVER NO.1
19. INSTALL ENGINE UNDER COVER ASSY (W/ ENGINE UNDER COVER ASSY)