EXHAUST PIPE (w/ DPF) INSTALLATION


  1. INSTALL CATALYTIC CONVERTER BRACKET SUB-ASSEMBLY


    1. Install the catalytic converter bracket with the bolt.

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

  2. INSTALL NO. 2 EXHAUST PIPE PROTECTOR


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

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

  3. INSTALL NO. 1 EXHAUST PIPE PROTECTOR


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

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

  4. INSTALL NO. 3 EXHAUST GAS TEMPERATURE SENSOR

    Note

    If the sensor is dropped, replace it with a new one.


    1. A003AI1E01

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

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

      Tech Tips


      • A003COCE02

        Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Text in Illustration
        *a Torque Wrench Fulcrum Length

      • When using a union nut wrench (fulcrum length of 25 mm (0.984 in.)) + torque wrench (fulcrum length of 180 mm (7.087 in.)): 26 N*m (268 kgf*cm, 19 ft.*lbf)

      • The sensor has 3 paint marks as shown in the illustration.

  5. INSTALL NO. 2 EXHAUST GAS TEMPERATURE SENSOR

    Note

    If the sensor is dropped, replace it with a new one.


    1. A003HL6E01
      Text in Illustration
      *a

      Wire Harness Tube Color

      (Orange)

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

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

  6. INSTALL EXHAUST GAS TEMPERATURE SENSOR

    Note

    If the sensor is dropped, replace it with a new one.


    1. A003EBBE01
      Text in Illustration
      *a

      Wire Harness Tube Color

      (Yellow)

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

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

  7. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. A003GJI

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

      Minimum free length
      40.5 mm (1.59 in.)

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

    2. A003FDFE08

      Using a plastic-faced hammer and wooden block, tap on a new gasket until its surface is flush with the front exhaust pipe.

      Note


      • Be sure to install the gasket so that it faces the correct direction.

      • Do not reuse the gasket.

      • Do not damage the gasket.

      • When connecting the exhaust pipe, do not push in the gasket with the exhaust pipe.

    3. Install a new gasket and the front exhaust pipe to the catalytic converter with pipe with 3 new nuts.

      Torque:
      63 N*m  { 642 kgf*cm, 46 ft.*lbf }

    4. Connect the front exhaust pipe to the 2 exhaust pipe supports.

    5. A003DCWE01
      Text in Illustration
      *a No. 1 Exhaust Pipe Air Hose Side
      *b No. 7 Exhaust Pipe Air Hose Side
      *c No. 1 Exhaust Pipe Air Hose Paint Mark (Green)
      *d front exhaust pipe Assembly Marking (Green)
      *e No. 7 Exhaust Pipe Air Hose Paint Mark (Pink)
      *f front exhaust pipe Assembly Marking (Pink)
      *g Stopper
      *h 4 to 10 mm

      Connect the No. 1 exhaust pipe air hose and No. 7 exhaust pipe air hose to the front exhaust pipe with 2 new clips.

      Note


      • Align the paint marks of the front exhaust pipe and exhaust pipe air hose and push on the exhaust pipe air hose until it contacts the stopper.

      • Make sure the clip is 4 to 10 mm (0.157 to 0.394 in.) from the end of the exhaust pipe air hose when installing the clip.

      • Make sure that there is no slack in the exhaust pipe air hose, and that it is not twisted or bent.

      • Take care not to damage the inner or outer surface of the exhaust pipe air hose when installing it. If the exhaust pipe air hose is damaged, replace it with a new one.

    6. Connect the No. 3 exhaust gas temperature sensor connector and attach the 2 clamps.

    7. Connect the No. 2 exhaust gas temperature sensor connector and attach the 2 clamps.

    8. Connect the exhaust gas temperature sensor connector and attach the clamp.

  8. INSTALL AIR FUEL RATIO SENSOR


    1. A003BGBE01

      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  { 402 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 attach the clamp.

  9. INSTALL AIR TUBE COVER


    1. Attach the 2 clips and clamp.

    2. Install the air tube cover with the 2 bolts.

      Torque:
      20 N*m  { 199 kgf*cm, 14 ft.*lbf }

  10. INSTALL CENTER EXHAUST PIPE ASSEMBLY


    1. except Super Long Wheelbase:

      Install the center exhaust pipe to the 3 exhaust pipe supports.

    2. for Super Long Wheelbase, for Type A:

      Install the center exhaust pipe to the 3 exhaust pipe supports.

    3. for Super Long Wheelbase, for Type B:

      Install the center exhaust pipe to the 4 exhaust pipe supports.

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

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

  11. INSTALL EXHAUST TAILPIPE ASSEMBLY


    1. Install the tailpipe to the exhaust pipe support.

    2. Install a new gasket and connect the tailpipe to the center exhaust pipe with the 2 bolts. Alternately tighten the bolts in several passes.

      Torque:
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }

      Note

      Do not reuse the gasket.

  12. INSPECT FOR EXHAUST GAS LEAK


    • If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.

  13. PERFORM CATALYST RECORD OF DPF THERMAL DETERIORATION CLEAR

    Click here