Exhaust Intermediate Pipe Replacement

^ Tools Required
- SA9168NE Exhaust and Tailpipe Cutter


Removal

CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED PRIOR TO LIFTING. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED. MAKE SURE HOIST DOES NOT CONTACT FUEL OR BRAKE LINES.

NOTICE: If the entire intermediate pipe and muffler assembly is being replaced, the service intermediate pipe must be shortened at the outlet end. Cut the intermediate pipe right behind the up-sized outlet end.





1. Raise vehicle squarely on a lift.
2. Remove (3) nuts (13 mm hex) at the outlet of the catalytic converter to intermediate pipe.





3. Remove catalytic converter gasket and discard.

NOTICE: Always use a chain cutter to cut the stainless steel exhaust system pipes.

IMPORTANT: The replacement intermediate pipe should be used as a guide to precisely locate the cut location on the pipe sector. Hold the replacement pipe up to the existing section and mark the cut location BEFORE cutting or removing the old pipe.





4. Using chain cutter SA1968NE (or equivalent), cut intermediate pipe in front of the rear suspension. Locate center 6) of the approximately 100 mm (4.0 inch) long straight section, mark the pipe, and make cut.
5. Disengage rubber isolator from hanger rod on intermediate pipe and remove pipe.


Installation





1. Position service intermediate pipe under vehicle.
2. Slide outlet end of intermediate pipe over remaining section of muffler inlet pipe.
3. Install new gasket at outlet of catalytic converter.
4. Install intermediate pipe to converter outlet using (3) fasteners (13 mm hex).
Torque: 25 Nm (19 ft. lbs.)
5. Install rubber isolator to hanger rod on intermediate pipe.

NOTICE: Locate muffler clamp 25 mm (1.0 inch)(2) from the end of the intermediate pipe and position clamp with U-bolt facing away from fuel tank.





6. Install pipe clamp at outlet end of intermediate pipe.
7. Align muffler and intermediate pipe, then tighten clamp.
Torque: 41 Nm (30 ft. lbs.)

IMPORTANT: Make sure that after installing the replacement exhaust sections that the system has not shifted rearward allowing contact between the hanger bracket screw (1) and the hanger block. This will cause noise; loosen the muffler strap and shift rearward on muffler to eliminate contact-retighten.

Torque: 22 Nm (16 ft. lbs.)





8. Check exhaust system for alignment and clearance to heat shields.
9. Start engine and check for leaks.

NOTICE: Position the muffler to ensure that there is 19 mm (3/4 inch) of clearance between the muffler and muffler ramp. If proper clearance can not be obtained, the intermediate pipe must be shortened.