EXHAUST PIPE (w/ DPF) INSTALLATION


  1. INSTALL LOWER NO. 2 EXHAUST PIPE PROTECTOR


    1. Install the lower No. 2 exhaust pipe protector with the 2 bolts.

      Torque:
      11 N*m  { 107 kgf*cm, 8 ft.*lbf }

  2. INSTALL LOWER NO. 1 EXHAUST PIPE PROTECTOR


    1. Install the lower No. 1 exhaust pipe protector with the 3 bolts.

      Torque:
      11 N*m  { 107 kgf*cm, 8 ft.*lbf }

  3. INSTALL EXHAUST GAS TEMPERATURE SENSOR


    1. Using a union nut wrench 14 mm, install the exhaust gas temperature sensor.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

    2. Using a union nut wrench 14 mm, install the No. 2 exhaust gas temperature sensor.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

    3. Using a union nut wrench 14 mm, install the No. 3 exhaust gas temperature sensor.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  4. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. Hang the front exhaust pipe assembly with the 2 No. 4 exhaust pipe supports.

    2. Install the new gasket onto the front exhaust pipe assembly.

    3. Install the front exhaust pipe assembly with the 3 new nuts.

      Torque:
      63 N*m  { 642 kgf*cm, 46 ft.*lbf }
    4. A01KGWFE02
      Text in Illustration
      *1 Spool
      *a Matchmarks
      *b 4 to 10 mm

      Connect the 2 exhaust pipe air hoses with the 2 new clips.

      Note


      • Align the matchmarks and insert the front exhaust pipe assembly into the air hose until the air hose contacts the spool of the front exhaust pipe assembly.

      • Install the clip approximately 4 mm (0.157 in.) to 10 mm (0.394 in.) from the tip of the air hose.

      • Make sure there is no slack in the air hose, and that it is not twisted, kinked, or creased.

      • Make sure not to damage the inner or outer surfaces of the air hose when installing it.

      • If the air hose is damaged in any way, replace it with a new one.

    5. Connect the No. 3 exhaust gas temperature sensor connector.

    6. Connect the exhaust gas temperature sensor connector.

    7. Install the heat insulator bracket with the bolt.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

  5. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY (w/ Front No. 2 Exhaust Pipe)

    A01KH07

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

      Minimum length
      40.5 mm (1.594 in.*lbf)

      If the length is not as specified, replace the compression spring.

    2. Hang the front No. 2 exhaust pipe assembly with the No. 4 exhaust pipe support.

    3. Install the new gasket onto the front exhaust pipe assembly.

    4. Install the front No. 2 exhaust pipe assembly with the 2 compression springs and 2 bolts.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  6. INSTALL CENTER EXHAUST PIPE ASSEMBLY (for Short and Long Wheelbase)

    A01KH07

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

      Minimum length
      40.5 mm (1.594 in.*lbf)

      If the length is not as specified, replace the compression spring.

    2. Hang the center exhaust pipe assembly with the 2 No. 4 exhaust pipe supports.

    3. Install the new gasket onto the front exhaust pipe assembly.

    4. Install the center exhaust pipe assembly with the 2 compression springs and 2 bolts.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

      Tech Tips

      After the installation, check that the gaps between the flanges of the exhaust manifold converter subassembly and front exhaust pipe assembly are consistent front-to-rear and left-to-right.

  7. INSTALL CENTER EXHAUST PIPE ASSEMBLY (for Super Long and Extra Super Long Wheelbase)

    A01KH07

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

      Minimum length
      40.5 mm (1.594 in.*lbf)

      If the length is not as specified, replace the compression spring.

    2. Hang the center exhaust pipe assembly with the 2 No. 4 exhaust pipe supports.

    3. Install the new gasket onto the front exhaust pipe assembly.

    4. Install the center exhaust pipe assembly with the 2 new nuts and 2 bolts.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

      Tech Tips

      After the installation, check that the gaps between the flanges of the exhaust manifold converter subassembly and front exhaust pipe assembly are consistent front-to-rear and left-to-right.

  8. INSTALL TAIL EXHAUST PIPE ASSEMBLY

    A01KGA2E01

    1. Install the new gasket onto the center exhaust pipe assembly.

    2. Install the tail exhaust pipe assembly with the 5 new nuts and 3 bolts.

      Torque:
      for nut A
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
      for nut B
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  9. INSTALL AIR FUEL RATIO SENSOR


    1. Using SST, install the air fuel ratio sensor to the front exhaust pipe.

      SST
      09224-00010
      Torque:
      without SST
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }
      with SST
      39 N*m  { 398 kgf*cm, 29. ft.*lbf }

      Tech Tips


      • Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification Click here.

      • Make sure SST and the wrench are connected in a straight line.

    2. Connect the air fuel ratio sensor connector and engage the wire harness clamp.

      Tech Tips

      Make sure that the part of the wire harness labeled A is as shown in the illustration.

  10. INSPECT FOR EXHAUST GAS LEAK