EXHAUST PIPE INSTALLATION

PROCEDURE


  1. INSTALL TAIL EXHAUST PIPE BAFFLE SUB-ASSEMBLY


    1. Install the tail exhaust pipe baffle sub-assembly to the tail exhaust pipe assembly with the 3 bolts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

    2. Install the tail exhaust pipe baffle sub-assembly to the tail exhaust pipe LH with the 3 bolts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  2. CONNECT TAIL EXHAUST PIPE LH


    1. Connect the tail exhaust pipe LH to the 3 exhaust pipe supports.

      Note

      Protect the rear bumper assembly using protection material such as a piece of cloth to avoid damage by the tail exhaust pipe baffle sub-assembly.

  3. CONNECT TAIL EXHAUST PIPE ASSEMBLY


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

      Note

      Protect the rear bumper assembly using protection material such as a piece of cloth to avoid damage by the tail exhaust pipe baffle sub-assembly.

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


    1. B003VCJ

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

      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 2 new gaskets to the front exhaust pipe assembly (TWC: Rear Catalyst) for tail exhaust pipe assembly and tail exhaust pipe LH side.

    3. B003T7DC47
      *1 Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
      *2 Gasket
      *a Wooden Block

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

      Note


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

      • Do not reuse the gaskets.

      • Do not damage the gaskets.

      • Do not push in the gaskets by using the front exhaust pipe assembly (TWC: Rear Catalyst) when connecting it.

    4. Install 2 new gaskets to the front exhaust pipe assembly (TWC: Rear Catalyst) for exhaust manifold sub-assembly LH (TWC: Front Catalyst) and exhaust manifold sub-assembly RH (TWC: Front Catalyst) side.

    5. Connect the front exhaust pipe assembly (TWC: Rear Catalyst) with 4 new nuts and 4 new bolts.

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }
    6. B003X5FC01
      *1 Tail Exhaust Pipe Assembly and Tail Exhaust Pipe LH
      *2 Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
      *3 Gasket
      *a Space between flanges: 6.5 mm (0.256 in.)

      Install the front exhaust pipe assembly (TWC: Rear Catalyst) to the tail exhaust pipe assembly and tail exhaust pipe LH with the 4 bolts and 4 compression springs.

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

      Tech Tips

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

  5. CONNECT HEATED OXYGEN SENSOR


    1. B003UDHC06
      *a 4 Turns

      Before installing the heated oxygen sensor, twist the sensor wire counterclockwise 4 turns.

    2. for Bank 2:


      1. B003T0WC01
        *a SST Fulcrum Length
        *b Torque Wrench Fulcrum Length

        Using SST, install the heated oxygen sensor to the front exhaust pipe assembly (TWC: Rear Catalyst).

        SST
        09224-00012
        Torque:
        Specified tightening torque
        44 N*m  { 449 kgf*cm, 32 ft.*lbf }

        Note


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

        • If the heated oxygen sensor has been struck or dropped, replace it.

        Tech Tips


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

          Click here

        • When using SST (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)):

          37.7 N*m (384 kgf*cm, 28 ft.*lbf)

      2. Connect the heated oxygen sensor grommet to the vehicle body.

    3. for Bank 1:


      1. B003WULC01
        *a SST Fulcrum Length
        *b Torque Wrench Fulcrum Length

        Using SST, install the heated oxygen sensor to the front exhaust pipe assembly (TWC: Rear Catalyst).

        SST
        09224-00012
        Torque:
        Specified tightening torque
        44 N*m  { 449 kgf*cm, 32 ft.*lbf }

        Note


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

        • If the heated oxygen sensor has been struck or dropped, replace it.

        Tech Tips


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

          Click here

        • When using SST (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)):

          37.7 N*m (384 kgf*cm, 28 ft.*lbf)

      2. Install the heated oxygen sensor grommet to the vehicle body.

  6. INSTALL FRONT CENTER FLOOR BRACE


    1. Engage the 2 clips.

    2. Install the front center floor brace to the vehicle body with the 6 bolts and 2 nuts.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  7. INSTALL REAR NO. 2 FLOOR BOARD SUB-ASSEMBLY

    Click here

  8. INSTALL REAR NO. 1 FLOOR BOARD SUB-ASSEMBLY

    Click here

  9. INSPECT FOR EXHAUST GAS LEAK

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


    1. Perform "Inspection After Repair" after repairing and replacing an exhaust gas leak.

      See page xxx