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.  Remove the battery cover. (SeeBATTERY REMOVAL/INSTALLATION [L3 Turbo].)

2.  Disconnect the negative battery cable.

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
Tunnel member
2
Member
3
TWC
(See TWC Removal Note.)
4
Seal ring (TWC side)
(See Seal Ring Removal Note.)
(See Seal Ring (TWC Side) Installation Note.)
5
Seal ring (WU-TWC side)
(See Silencer Removal Note.)
(See Seal Ring (WU-TWC Side) Installation Note.)
6
HO2S
(See A/F Sensor, HO2S Removal Note.)
7
Silencer
(See Silencer Removal Note.)
8
Exhaust manifold insulator (Upper)
(See Exhaust Manifold Insulator (Upper) Removal Note.)
9
Insulator
(See Insulator Removal Note (R.H.D.))
10
Exhaust manifold insulator (Lower)
11
A/F sensor
(See A/F Sensor, HO2S Removal Note.)
12
WU-TWC insulator
13
WU-TWC bracket
14
WU-TWC
(See WU-TWC Removal Note.)
(See WU-TWC Installation Note.)
15
Exhaust manifold
(See Exhaust Manifold Installation Note.)
16
Exhaust manifold gasket


TWC Removal Note

1.  Disconnect the hanger rubber except for the one installed to the rear end of the vehicle from the silencer, and suspend the silencer using rope.

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2.  Remove the TWC.


Seal Ring Removal Note

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

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A/F Sensor, HO2S Removal Note

1.  Remove the A/F sensor, HO2S using the SST before removing the exhaust manifold.

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Silencer Removal Note

1.  Remove the rear shock absorber lower bolts. (See REAR SHOCK ABSORBER REMOVAL/INSTALLATION.)

2.  Loosen the rear crossmember component installation bolts (6 locations) and lower the rear crossmember component approx. 70 mm {2.8 in}. (See REAR CROSSMEMBER REMOVAL/INSTALLATION.)

3.  Remove the main silencer.


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.)

Caution
•  If the insulator contacts the cooler pipe No.3 during removal, the cooler pipe No.3 will be damaged. Therefore, wrap the cooler pipe No.3 with tape to protect it.

1.  Remove the cooler hose (LO) installation nut and set it out of the way. (See REFRIGERANT LINE REMOVAL/INSTALLATION [L3 Turbo].)

2.  Remove the power steering reserve tank installation bolt and set it out of the way. (See POWER STEERING OIL PUMP REMOVAL/INSTALLATION [L3 Turbo].)

3.  Detach the cooler pipe No.3 installation clips and set the cooler pipe No.3 out of the way. (See REFRIGERANT LINE REMOVAL/INSTALLATION [L3 Turbo].)

4.  Disconnect the brake vacuum hose.

5.  Remove the insulator.


WU-TWC Removal Note

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

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2.  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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Seal Ring (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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