EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2]

id0115z7800200

Replacement Part

Gasket
 
Quantity: 1
 
Location of use: Main silencer
Nut
 
Quantity: 4
 
Location of use: Middle pipe
Gasket
 
Quantity: 1
 
Location of use: Middle pipe
Gasket
 
Quantity: 3
 
Location of use: Catalytic converter
Washer
 
Quantity: 2
 
Location of use: Catalytic converter
Gasket
 
Quantity: 1
 
Location of use: Exhaust manifold
Nut
 
Quantity: 10
 
Location of use: Exhaust manifold
Stud
 
Quantity: 10
 
Location of use: Exhaust manifold
Exhaust gas pressure hose
 
Quantity: 2
 
Location of use: Catalytic converter
Clip
 
Quantity: 2
 
Location of use: Catalytic converter
—
—

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.
Caution
•  Perform exhaust gas temperature sensor removal/installation only when inspection or replacement is required, such as when DTCs for the sensor are displayed, because it may cause exhaust gas leakage. If the exhaust gas temperature sensor is removed/installed once, always verify that there is no exhaust gas leakage after reinstallation.
Note
•  If the catalytic converter is replaced, perform the “Operation After Replacing Catalytic Converter” procedure.

Operation After Replacing Catalytic Converter

1.  If the catalytic converter is replaced, perform the following procedure.

STEP

ACTION

PAGE/CONDITION
1
Perform diesel particulate filter data reset procedure.
(See DIESEL PARTICULATE FILTER DATA RESET [SKYACTIV-D 2.2].)
2
Switch the ignition off.
—
3
Wait for 30 s.
—
4
Switch the ignition ON (engine off).
—
5
Perform KOEO self-test procedure.
(See KOEO/KOER SELF TEST [PCM (SKYACTIV-D 2.2)].)
6
Perform KOER self-test procedure.
(See KOEO/KOER SELF TEST [PCM (SKYACTIV-D 2.2)].)
7
Perform compulsory diesel particulate filter regeneration.
(See COMPULSORY DIESEL PARTICULATE FILTER REGENERATION [SKYACTIV-D 2.2].)
8
Clear the DTCs.
(See OBD READ/CLEAR DIAGNOSTIC TEST RESULTS [PCM (SKYACTIV-D 2.2)].)


Exhaust System Removal/Installation (2WD)

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

2.  Remove in the order shown in the figure.

3.  Remove the exhaust system insulator. (See Exhaust system insulator removal/installation.)

4.  Install in the reverse order of removal.

Step 1 (Without SCR system)

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1
Main silencer
2
Insulator
3
Brace bar
(See Brace bar removal note.)
4
Tunnel member
5
Middle pipe

Step 1 (With SCR system)

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1
Main silencer
2
Plate
3
Brace bar
4
Tunnel member
5
NOx sensor No.1
(See NOx SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
6
Urea injector
(See UREA INJECTOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
7
Exhaust gas temperature sensor No.5
(See EXHAUST GAS TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
8
NOx sensor No.2
(See NOx SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
9
PM sensor
(See PM SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
10
SCR converter

Step 2

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1
Insulator
(See Insulator removal note.)
2
Catalytic converter insulator
(See Catalytic converter insulator removal note.)
(See Catalytic converter insulator installation note.)
3
Exhaust gas pressure hose
4
Catalytic converter upper bracket
(See Catalytic converter bracket installation note.)
5
Catalytic converter lower bracket
(See Catalytic converter lower bracket removal note.)
(See Catalytic converter bracket installation note.)
6
Catalytic converter
(See Catalytic converter removal note.)
(See Catalytic converter installation note.)
(See Operation After Replacing Catalytic Converter.)
7
A/F sensor
(See AIR FUEL RATIO (A/F) SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
8
Exhaust gas temperature sensor No.4 (With SCR system)
(See EXHAUST GAS TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
9
Exhaust gas temperature sensor No.3
(See EXHAUST GAS TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
10
Exhaust gas temperature sensor No.2
(See EXHAUST GAS TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
11
Exhaust gas temperature sensor No.1
(See EXHAUST GAS TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
12
Insulator
13
Exhaust gas pressure sensor No.1 component
14
Exhaust manifold insulator
15
Exhaust manifold
(See Exhaust manifold removal note.)
(See Exhaust manifold installation note.)


Exhaust system insulator removal/installation

1.  Remove in the order shown in the figure.

2.  Install in the reverse order of removal.

Without SCR system

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1
Insulator (rear)
(See Insulator (rear) removal note.)
2
Insulator (middle)
3
Insulator (front)

With SCR system

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1
Insulator (rear)
(See Insulator (rear) removal note.)
2
Insulator (middle)
3
Insulator (front)


Insulator (rear) removal note

Note
•  If re-installed, use the same rivets.

1.  Using a hammer and punch (diam. 2—2.8 mm{0.08—0.11 in}), punch out the mandrel.

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2.  Pull out and remove the flange using a drill (diam. 5 mm{0.2 in}).

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Brace bar removal note

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

2.  Remove the brace bar.


Insulator removal note

1.  Remove the windshield wiper arm and blade. (See WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION.)

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

3.  Remove the windshield wiper motor and link. (See WINDSHIELD WIPER MOTOR AND LINK REMOVAL/INSTALLATION.)

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

5.  Remove the insulator.


Catalytic converter insulator removal note

1.  Disconnect the exhaust gas temperature sensor No.2 connector. (See EXHAUST GAS TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

2.  Remove the nut shown in the figure. (See EXHAUST GAS TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

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3.  Remove the wiring harness clip shown in the figure.

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4.  Remove the catalytic converter insulator.


Catalytic converter lower bracket removal note

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

2.  Remove the catalytic converter lower bracket.


Catalytic converter removal note

1.  Disconnect the exhaust gas temperature sensor No.3 connector.

2.  Disconnect the A/F sensor connector.

3.  Remove the catalytic converter.


Exhaust manifold removal note

1.  Remove the turbocharger. (See TURBOCHARGER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

2.  Set the exhaust gas temperature sensor No.1 out of the way. (See EXHAUST GAS TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

3.  Remove the exhaust gas pressure sensor No.1 component.

4.  Remove the exhaust manifold insulator.

5.  Remove the exhaust manifold.


Exhaust manifold installation note

1.  Install the new studs to the cylinder head.

2.  Tighten the nuts in the other shown in the figure.

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Tightening torque
40—47 N·m {4.1—4.7 kgf·m, 30—34 ft·lbf}

3.  Tighten the nuts in the other shown in the figure.


Catalytic converter installation note

1.  Temporarily tighten bolt and nuts shown in the figure.

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2.  Tighten the bolt and nuts in the other shown in the figure.

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Tightening torque
45—62 N·m {4.6—6.3 kgf·m, 34—45 ft·lbf}

3.  After installation, verify that the tightening torque for the bolt and nuts is correct.


Catalytic converter bracket installation note

1.  Temporarily tighten bolts 1 and bolt 2 shown in the figure.

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2.  Tighten bolts 1 shown in the figure.

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

3.  Tighten bolts 2 shown in the figure.

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

4.  All the conclusions check after attachment whether it is the right torque.

5.  Temporarily tighten bolts 3 and bolt 4 shown in the figure.

ac8jjw00002111

6.  Tighten the bolts in the order shown in the figure.

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

7.  Temporarily tighten bolts 5 and bolt 6 shown in the figure.

ac8jjw00002112

8.  Tighten the bolts in the order shown in the figure.

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

9.  All the conclusions check after attachment whether it is the right torque.


Catalytic converter insulator installation note

1.  Temporarily tighten the catalytic converter insulator installation bolts.

2.  Tighten the bolts 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}


Exhaust System Removal/Installation (4WD)

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

2.  Remove in the order shown in the figure.

3.  Remove the exhaust system insulator. (See Catalytic converter bracket installation note.)

4.  Install in the reverse order of removal.

Step 1 (Without SCR system)

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1
Main silencer
2
Middle pipe

Step 1 (With SCR system)

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1
Main silencer
2
Plate
3
Brace bar
4
Tunnel member
5
NOx sensor No.1
(See NOx SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
6
Urea injector
(See UREA INJECTOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
7
Exhaust gas temperature sensor No.5
(See EXHAUST GAS TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
8
NOx sensor No.2
(See NOx SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
9
PM sensor
(See PM SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
10
SCR converter

Step 2

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1
Insulator
(See Insulator removal note.)
2
Catalytic converter insulator
(See Catalytic converter insulator removal note.)
(See Catalytic converter insulator installation note.)
3
Exhaust gas pressure hose
4
Catalytic converter upper bracket
(See Catalytic converter bracket installation note.)
5
Catalytic converter lower bracket
(See Catalytic converter lower bracket removal note.)
(See Catalytic converter bracket installation note.)
6
Catalytic converter
(See Catalytic converter removal note.)
(See Catalytic converter installation note.)
(See Operation After Replacing Catalytic Converter.)
7
A/F sensor
(See AIR FUEL RATIO (A/F) SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
8
Exhaust gas temperature sensor No.4 (With SCR system)
(See EXHAUST GAS TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
9
Exhaust gas temperature sensor No.3
(See EXHAUST GAS TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
10
Exhaust gas temperature sensor No.2
(See EXHAUST GAS TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
11
Exhaust gas temperature sensor No.1
(See EXHAUST GAS TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
12
Insulator
13
Exhaust gas pressure sensor No.1 component
14
Exhaust manifold insulator
15
Exhaust manifold
(See Exhaust manifold removal note.)
(See Exhaust manifold installation note.)


Exhaust system insulator removal/installation

1.  Remove the propeller shaft. (See PROPELLER SHAFT REMOVAL/INSTALLATION.)

2.  Remove in the order shown in the figure.

3.  Install in the reverse order of removal.

Without SCR system

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1
Insulator (rear)
(See Catalytic converter insulator installation note.)
2
Insulator (middle)
3
Insulator (front)

With SCR system

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1
Insulator (rear)
(See Insulator (rear) removal note.)
2
Insulator (middle)
3
Insulator (front)


Insulator (rear) removal note

Note
•  If re-installed, use the same rivets.

1.  Using a hammer and punch (diam. 2—2.8 mm {0.08—0.11}), punch out the mandrel.

ac5wzw00005810

2.  Pull out and remove the flange using a drill (diam. 5 mm {0.2 in})

ac5wzw00005811


Insulator removal note

1.  Remove the windshield wiper arm and blade. (See WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION.)

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

3.  Disconnect the windshield wiper de-icer connector. (See WINDSHIELD REMOVAL.)(See WINDSHIELD INSTALLATION.)

4.  Remove the windshield wiper motor and link. (See WINDSHIELD WIPER MOTOR AND LINK REMOVAL/INSTALLATION.)

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

6.  Remove the insulator.


Catalytic converter insulator removal note

1.  Disconnect the exhaust gas temperature sensor No.2 connector. (See EXHAUST GAS TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

2.  Remove the nut shown in the figure. (See EXHAUST GAS TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

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3.  Remove the wiring harness clip shown in the figure.

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4.  Remove the catalytic converter insulator.


Catalytic converter lower bracket removal note

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

2.  Remove the catalytic converter lower bracket.


Catalytic converter removal note

1.  Disconnect the exhaust temperature sensor No.3 connector.

2.  Disconnect the A/F sensor connector.

3.  Remove the catalytic converter.


Exhaust manifold removal note

1.  Remove the turbocharger. (See TURBOCHARGER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

2.  Set the exhaust gas temperature sensor No.1 out of the way. (See EXHAUST GAS TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

3.  Remove the exhaust gas pressure sensor No.1 component.

4.  Remove the exhaust manifold insulator.

5.  Remove the exhaust manifold.


Exhaust manifold installation note

1.  Install the new studs to the cylinder head.

2.  Tighten the nuts in the other shown in the figure.

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Tightening torque
40—47 N·m {4.1—4.7 kgf·m, 30—34 ft·lbf}

3.  Tighten the nuts in the other shown in the figure.


Catalytic converter installation note

1.  Temporarily tighten bolt and nuts shown in the figure.

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2.  Tighten the bolt and nuts in the other shown in the figure.

ac8jjw00002109

Tightening torque
45—62 N·m {4.6—6.3 kgf·m, 34—45 ft·lbf}

3.  After installation, verify that the tightening torque for the bolt and nuts is correct.


Catalytic converter bracket installation note

1.  Temporarily tighten bolts 1 and bolt 2 shown in the figure.

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2.  Tighten bolts 1 shown in the figure.

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

3.  Tighten bolts 2 shown in the figure.

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

4.  All the conclusions check after attachment whether it is the right torque.

5.  Temporarily tighten bolts 3 and bolt 4 shown in the figure.

ac8jjw00002111

6.  Tighten the bolts in the order shown in the figure.

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

7.  Temporarily tighten bolts 5 and bolt 6 shown in the figure.

ac8jjw00002112

8.  Tighten the bolts in the order shown in the figure.

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

9.  All the conclusions check after attachment whether it is the right torque.


Catalytic converter insulator installation note

1.  Temporarily tighten the catalytic converter insulator installation bolts.

2.  Tighten the bolts in the order shown in the figure.

ac8jjw00002113

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