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EXHAUST SYSTEM REMOVAL/INSTALLATION [WITH WU-TWC]

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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 in the order indicated in the table.

3. Install in the reverse order of removal.

1 | Main silencer
2 | Crossmember
3 | Member
4 | Catalytic converter
5 | Seal ring (See Seal Ring Removal Note.) (See Seal Ring Installation Note.)
6 | HO2S (See HO2S Removal Note)
7 | EGR pipe (exhaust manifold side) (with EGR system) (See EGR Pipe Installation Note)
8 | EGR valve bracket (with EGR system)
9 | Exhaust manifold insulator (See Exhaust Manifold Insulator Removal Note)
10 | Exhaust manifold (See Exhaust Manifold Removal Note)

## Seal Ring Removal Note

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

## HO2S Removal Note

1. Remove the HO2S using the SST.

## Exhaust Manifold Insulator Removal Note

1. Remove the front suspension tower bar for easier access.

## Exhaust Manifold Removal Note

1. Remove the following parts for easier access.

  • Front crossmember
  • Front stabilizer
  • Front lower arm
  • Steering gear and linkage

## EGR Pipe Installation Note

1. Install the EGR pipe installation bolts and nuts.

2. Tighten the EGR pipe installation bolts and nuts in the order shown in the figure.

## Seal Ring 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.