EXHAUST PIPE INSTALLATION

PROCEDURE

1. INSTALL TAIL EXHAUST PIPE BAFFLE SUB-ASSEMBLY (w/ Tail Exhaust Pipe Baffle)

   1. Set a new tail exhaust pipe baffle sub-assembly to the tail exhaust pipe assembly.

   2. 

      *a	Plastic Hammer
      *b	Protrusion
      *c	Cutout

      Align the cutout of the tail exhaust pipe baffle sub-assembly with the protrusion of the tail exhaust pipe assembly as shown in the illustration.

   3. Using a plastic hammer, uniformly tap the tail exhaust pipe baffle sub-assembly onto the tail exhaust pipe assembly.

2. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)

   1. 

      Using a vernier caliper, measure the free length of the compression spring.

      Standard Length	43 mm (1.69 in.)
      Minimum Free Length	41.5 mm (1.63 in.)

      If the free length is less than the minimum, replace the compression spring.

   2. Temporarily install a new exhaust pipe gasket to the exhaust manifold converter sub-assembly (TWC: Front Catalyst).

   3. 

      *1	Exhaust Manifold Converter Sub-assembly (TWC: Front Catalyst)
      *2	Exhaust Pipe Gasket
      *a	Wooden Block

      Using a plastic hammer and wooden block, tap in the exhaust pipe gasket until its surface is flush with the exhaust manifold converter sub-assembly (TWC: Front Catalyst).

      Note:

      • Be sure to install the exhaust pipe gasket in the correct direction.

      • Do not reuse the exhaust pipe gasket.

      • Do not damage the exhaust pipe gasket.

      • Do not push in the exhaust pipe gasket by using the exhaust pipe when connecting it.

   4. 

      *1	Exhaust Manifold Converter Sub-assembly (TWC: Front Catalyst)
      *2	Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
      *3	Exhaust Pipe Gasket
      *a	Space between Flanges: 8.5 mm (0.335 in.)

      Install the front exhaust pipe assembly (TWC: Rear Catalyst) to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) with the 2 compression springs and 2 bolts.

      43 N*m

      438 kgf*cm

      32 ft.*lbf

      Tip:

      After installation, check that the space between the flanges of the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and front exhaust pipe assembly (TWC: Rear Catalyst) is consistent front-to-rear and left-to-right.

3. INSTALL FRONT CENTER FLOOR BRACE SUB-ASSEMBLY

   1. Install the front center floor brace sub-assembly to the vehicle body with the 4 bolts.

      51 N*m

      520 kgf*cm

      38 ft.*lbf

4. INSTALL TAIL EXHAUST PIPE ASSEMBLY

   1. 

      Using a vernier caliper, measure the free length of the compression spring.

      Standard Length	40 mm (1.57 in.)
      Minimum Free Length	38.5 mm (1.52 in.)

      If the free length is less than the minimum, replace the compression spring.

   2. Temporarily install a new exhaust pipe gasket to the front exhaust pipe assembly (TWC: Rear Catalyst).

   3. 

      *1	Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
      *2	Exhaust Pipe Gasket
      *a	Wooden Block

      Using a plastic hammer and wooden block, tap in the exhaust pipe gasket until its surface is flush with the front exhaust pipe assembly (TWC: Rear Catalyst).

      Note:

      • Be sure to install the gasket in the correct direction.

      • Do not reuse the gasket.

      • Do not damage the gasket.

      • Do not push in the gasket by using the exhaust pipes when connecting them.

   4. Connect the tail exhaust pipe assembly to the 3 exhaust pipe supports.

   5. 

      *1	Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
      *2	Tail Exhaust Pipe Assembly
      *3	Exhaust Pipe Gasket
      *a	Space between Flanges: 6.5 mm (0.256 in.)

      Install the tail exhaust pipe assembly to the front exhaust pipe assembly (TWC: Rear Catalyst) with the 2 compression springs and 2 bolts.

      43 N*m

      438 kgf*cm

      32 ft.*lbf

      Tip:

      After installation, check that the space between the flanges of the front exhaust pipe assembly (TWC: Rear Catalyst) and tail exhaust pipe assembly is consistent front-to-rear and left-to-right.

5. INSTALL HEATED OXYGEN SENSOR

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