EXHAUST SYSTEM REMOVAL/INSTALLATION [L3 Turbo]

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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.

2.  Remove the charge air cooler duct.

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

4.  Remove in the order indicated in the table.

5.  Install in the reverse order of removal.

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1
Main silencer
(See Main Silencer Installation Note.)
2
Seal ring (middle pipe side)
(See Seal Ring Removal Note.)
(See Seal Ring (Middle Pipe Side) Installation Note.)
3
Middle pipe
4
HO2S
(See AIR FUEL RATIO (A/F) SENSOR, HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [L3 Turbo])
5
Front pipe
(See Front Pipe Installation Note)
6
Seal ring (WU-TWC side)
(See Seal Ring Removal Note.)
(See Seal Ring (WU-TWC Side) Installation Note.)
7
Exhaust manifold insulator (Upper) (See Exhaust Manifold Insulator (Upper) Removal Note)
8
Insulator (R.H.D.)
(See Insulator Removal Note (R.H.D.).)
9
A/F sensor
(SeeAIR FUEL RATIO (A/F) SENSOR, HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [L3 Turbo].)
10
Exhaust manifold insulator (Lower)
11
WU-TWC insulator
12
WU-TWC bracket
13
WU-TWC
(See WU-TWC Removal Note (2WD))
(See WU-TWC Removal Note (4WD))
(See WU-TWC Installation Note.)
14
Clip
15
Exhaust manifold
(See Exhaust Manifold Installation Note)
16
Exhaust manifold gasket


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.

2.  Remove the exhaust manifold insulator (upper).


Insulator Removal Note (R.H.D.)

1.  Set the blake vacuum hose out of the way. (See VACUUM HOSE REMOVAL/INSTALLATION.)

2.  Remove the Insulator.


WU-TWC Removal Note (2WD)

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

2.  Remove the WU-TWC.


WU-TWC Removal Note (4WD)

1.  Remove the cowl grille.

2.  Remove the windshield wiper motor.

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.

6.  Remove the WU-TWC.


Exhaust Manifold Installation Note

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

Tightening torque
43—64 N·m {4.4—6.5 kgf·m, 32—47 ft·lbf}
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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.

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

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

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

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

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


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).