EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5 (WITH CYLINDER DEACTIVATION)]

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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 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

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1
Main silencer
2
Insulator
(See Insulator Installation Note.)
3
Brace bar
(See Brace Bar Removal Note.)
(See Brace Bar Installation Note.)
4
HO2S
(See HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [SKYACTIV-G 2.5 (WITH CYLINDER DEACTIVATION)].)
5
Tunnel member
(See Tunnel Member Installation Note.)
6
Wiring harness
7
TWC

Step 2

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1
A/F sensor
(See AIR FUEL RATIO (A/F) SENSOR REMOVAL/INSTALLATION [SKYACTIV-G 2.5 (WITH CYLINDER DEACTIVATION)].)
2
Clip
3
Insulator
4
Exhaust manifold insulator
(See Exhaust Manifold Insulator Removal Note.)
(See Exhaust Manifold Insulator Installation Note.)
5
Exhaust manifold (WU-TWC)
(See Exhaust Manifold Removal Note.)
(See Exhaust Manifold Installation Note.)
6
Exhaust manifold gasket


Exhaust system insulator removal/installation

1.  Remove in the order indicated in the table.

2.  Install in the reverse order of removal.

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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).

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

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Brace Bar Removal Note

1.  Remove the floor under cover. (See FLOOR UNDER COVER REMOVAL/INSTALLATION.)

2.  Remove the brace bar.


Exhaust Manifold Insulator Removal Note

1.  Remove the No. 1 engine mount rubber bolt (transmission side), and loosen the No. 1 engine mount rubber bolt (front crossmember side) to slightly move the engine. (SeeENGINE MOUNT DISASSEMBLY/ASSEMBLY [SKYACTIV-G 2.5 (WITH CYLINDER DEACTIVATION)].)

2.  Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.5 (WITH CYLINDER DEACTIVATION)].)

3.  Remove the bolts shown in the figure.

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4.  Disconnect the wiring harness clip shown in the figure.

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5.  Set the purge solenoid valve component aside so that it does not interfere with the servicing.

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6.  Remove the insulators shown in the figure.

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7.  Remove the exhaust manifold insulator.


Exhaust Manifold Removal Note

Note
•  When removing the exhaust manifold, the bracket installed under the exhaust manifold does not have to be removed. Remove the exhaust manifold with the bracket installed.

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

2.  Remove the exhaust manifold.


Exhaust Manifold Installation Note

1.  Temporarily tighten the exhaust manifold installation nuts (1) and (2) shown in the figure by hand.

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2.  Tighten the exhaust manifold installation nuts (1) and (2) shown in the figure to 33—53 N·m {3.4—5.4 kgf·m, 25—39 ft·lbf}.

3.  Temporarily tighten the exhaust manifold installation nuts (3) to (5) shown in the figure by hand.

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4.  Tighten the exhaust manifold installation nuts (3) to (5) shown in the figure.

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

5.  Tighten the exhaust manifold installation nuts (1) and (2) shown in the figure.

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

6.  Temporarily tighten the bolts (6) and (7) shown in the figure.

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7.  Tighten the bolt (6) shown in the figure.

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

8.  Tighten the bolt (7) shown in the figure.

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

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


Exhaust Manifold Insulator Installation Note

1.  Temporarily tighten the exhaust manifold insulator.

2.  Tighten the exhaust manifold insulator in the order shown in the figure.

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

3.  Install the insulators shown in the figure.

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Tightening torque
8—11 N·m {82—112 kgf·cm, 71—97 in·lbf}

4.  Install the purge solenoid valve component.

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5.  Install the wiring harness clip shown in the figure.

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6.  Install the bolts shown in the figure.

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Tightening torque
8—11 N·m {82—112 kgf·cm, 71—97 in·lbf}

7.  Install the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.5 (WITH CYLINDER DEACTIVATION)].)

8.  Install the No.1 engine mount rubber bolt (transmission side), and the No.1 engine mount rubber bolt (front crossmember side). (See ENGINE MOUNT DISASSEMBLY/ASSEMBLY [SKYACTIV-G 2.5 (WITH CYLINDER DEACTIVATION)].)


Insulator (Front) Installation Note

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

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

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

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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 (Rear) Installation Note

1.  Install rivets A shown in the figure.

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2.  Install the remaining rivets.


Tunnel Member Installation Note

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

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Tightening torque
18—26 N·m {1.9—2.6 kgf·m, 14—19 ft·lbf}

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

Tightening torque
18—26 N·m {1.9—2.6 kgf·m, 14—19 ft·lbf}

3.  Tighten the remaining bolts to the specified torque.

Tightening torque
18—26 N·m {1.9—2.6 kgf·m, 14—19 ft·lbf}


Brace Bar Installation Note

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

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Tightening torque
18—26 N·m {1.9—2.6 kgf·m, 14—19 ft·lbf}

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

Tightening torque
18—26 N·m {1.9—2.6 kgf·m, 14—19 ft·lbf}

3.  Tighten the remaining bolts to the specified torque.

Tightening torque
18—26 N·m {1.9—2.6 kgf·m, 14—19 ft·lbf}

4.  Install the floor under cover. (See FLOOR UNDER COVER REMOVAL/INSTALLATION.)


Insulator Installation Note

1.  Install fastener A shown in the figure.

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2.  Install fastener B shown in the figure.

3.  Install the remaining fasteners.

4.  Tighten the bolts shown in the figure to the specified torque.

Tightening torque
7—9 N·m {72—91 kgf·cm, 62—79 in·lbf}