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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.Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [L3 Turbo].)

2.Remove the charge air cooler cover and charge air cooler. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [L3 Turbo])

3.Remove in the order indicated in the table.

4.Remove the exhaust system insulator. (See Exhaust System Insulator Removal/installation Note.)

5.Install in the reverse order of removal.

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Exhaust System Insulator Removal/installation Note

1.Remove the exhaust system insulator in the order shown in the figure.

2.Install in the reverse order of removal.

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Seal Ring Removal Note

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

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Exhaust Manifold Insulator (Upper) Removal Note

1.Remove the charge air cooler bracket. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [L3 Turbo].)

2.Remove the exhaust manifold insulator (upper).

WU-TWC Removal Note (4WD)

1.Remove the cowl grille. (See COWL GRILLE REMOVAL/INSTALLATION.)

2.Remove the windshield wiper motor. (See WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION.)

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

4.Remove the generator duct. (See GENERATOR REMOVAL/INSTALLATION [L3 Turbo])

5.Set the generator out of the way. (See GENERATOR REMOVAL/INSTALLATION [L3 Turbo].)

6.Remove the WU-TWC.

Exhaust Manifold Installation Note

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

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WU-TWC Installation Note

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

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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.

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

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

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.

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

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

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Front Pipe Installation Note

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

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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 (Middle Pipe 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.

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

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

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Main Silencer Installation Note

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

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