EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5T]

id0115q4800200

Replacement Part

Gasket
 
Quantity: 1
 
Location of use: Main silencer
Nut
 
Quantity: 4
 
Location of use: TWC
Gasket
 
Quantity: 2
 
Location of use: WU-TWC
Nut
 
Quantity: 5
 
Location of use: WU-TWC
Gasket
 
Quantity: 1
 
Location of use: Dynamic pressure turbo
Nut
 
Quantity: 6
 
Location of use: Exhaust manifold
Gasket
 
Quantity: 1
 
Location of use: Exhaust manifold
RIVET
 
Quantity: 5
 
Location of use: Insulator (rear)
—

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.

Exhaust System Removal/Installation

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

2.  Remove in the order indicated in the table.

3.  Remove the insulator. (See Exhaust System Insulator Removal/Installation.)

4.  Install in the reverse order of removal.

Step 1

ac5uuw00010510

1
Main silencer
2
HO2S
(See HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)
3
TWC

Step 2

ac5wzw00014318

1
Insulator
(See Insulator removal note.)
(See Insulator installation note.)
2
A/F sensor
(See AIR FUEL RATIO (A/F) SENSOR REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)
3
WU-TWC insulator No.1
(See WU-TWC insulator No.1 installation note.)
4
WU-TWC
(See WU-TWC installation note.)
5
WU-TWC insulator No.2
6
Dynamic pressure turbo
(See DYNAMIC PRESSURE TURBO REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)
7
Exhaust manifold
(See Exhaust manifold installation note.)


Insulator removal note

1.  Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

2.  Remove the cowl panel. (See COWL PANEL REMOVAL/INSTALLATION.)

3.  Remove the front crossmember. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)

4.  Remove the insulator.


Exhaust manifold installation note

1.  Tighten the nuts in the order shown in the figure.

ac5uuw00010552

Tightening torque
45—52 N·m {4.6—5.5 kgf·m, 34—38 ft·lbf}


WU-TWC installation note

1.  Temporarily tighten the WU-TWC installation nuts.

ac5uuw00010553

2.  Tighten the WU-TWC installation nuts in the order shown in the figure to the specified torque.

Tightening torque
45—62 N·m {4.6—6.3 kgf·m, 34—45 ft·lbf}

3.  Temporarily tighten the WU-TWC installation bolt.

4.  Tighten the WU-TWC installation bolt to the specified torque.

Tightening torque
38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}


WU-TWC insulator No.1 installation note

1.  Temporarily tighten the WU-TWC insulator No.1 installation bolts.

ac9uuw00009494

2.  Tighten the bolts in the order shown in the figure.

Tightening torque
8—10 N·m {82—101 kgf·cm, 71—88 in·lbf}


Insulator installation note

1.  Install the insulator.

2.  Install the front crossmember. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)

3.  Install the cowl panel. (See COWL PANEL REMOVAL/INSTALLATION.)

4.  Install the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)


Exhaust System Insulator Removal/Installation

1.  Remove the propeller shaft. (See PROPELLER SHAFT REMOVAL/INSTALLATION.)

2.  Remove in the order indicated in the table.

3.  Install in the reverse order of removal.

ac5uuw00010511

1
Insulator (rear)
(See Insulator (rear) removal note.)
(See Insulator (rear) installation note.)
2
Insulator (middle)
(See Insulator (middle) installation note.)
3
Insulator (front)
(See Insulator (front) installation note.)


Insulator (rear) removal note

Note
•  The insulator (rear) are installed using rivets.

1.  Push out the mandrel using a hammer and punch (2—2.8 mm {0.08—0.11 in} diameter).

ac5uuw00000434

2.  Remove the flange using a drill (5 mm {0.20 in} drill bit).

ar8uuw00001479


Insulator (front) installation note

1.  Tighten nut A shown in the figure to the specified torque.

ac5uuw00010507

Tightening torque
8—10 N·m {82—101 kgf·cm, 71—88 in·lbf}

2.  Tighten nut B shown in the figure to the specified torque.

Tightening torque
8—10 N·m {82—101 kgf·cm, 71—88 in·lbf}

3.  Tighten the remaining nuts to the specified torque.

Tightening torque
8—10 N·m {82—101 kgf·cm, 71—88 in·lbf}


Insulator (middle) installation note

1.  Install the fasteners shown in the figure.

ac5uuw00010508

2.  Tighten the nuts shown in the figure to the specified torque.

Tightening torque
8—10 N·m {82—101 kgf·cm, 71—88 in·lbf}


Insulator (rear) installation note

1.  Install rivets A shown in the figure.

ac5uuw00010509

2.  Install the remaining rivets.