EXHAUST PIPE (w/ DPF) INSTALLATION

CAUTION:


  • Wear protective gloves and protective glasses when installing the exhaust pipe.

  • The exhaust pipe is extremely hot immediately after the engine has stopped.

  • Confirm that the exhaust pipe has cooled down before removing it.


  1. INSTALL EXHAUST GAS TEMPERATURE SENSOR

    Note

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


    1. Using a 14 mm union nut wrench, install the 2 exhaust gas temperature sensors.

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

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

      Tech Tips

      The identification tape on the exhaust gas temperature sensor is pink.

  2. INSTALL NO. 2 EXHAUST GAS TEMPERATURE SENSOR

    Note

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


    1. 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 }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

      Tech Tips

      The identification tape on the exhaust gas temperature sensor is white.

  3. INSTALL NO. 3 EXHAUST GAS TEMPERATURE SENSOR

    Note

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


    1. 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 }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

      Tech Tips

      The identification tape on the exhaust gas temperature sensor is gray.

  4. INSTALL MONOLITHIC CONVERTER ASSEMBLY LH


    1. Install a new gasket to the turbocharger.

      Tech Tips

      Make sure that the claw of the gasket faces downward.

    2. A015BI0E01

      Install the monolithic converter LH with 3 new nuts.

      Torque:
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }

    3. Temporarily install the No. 2 manifold stay with the 3 bolts.

    4. Tighten the 2 bolts labeled A in the illustration first, and then tighten the bolt labeled B in the illustration.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
    5. A015CS6E01
      Text in Illustration
      *1 Tape

      Attach the 4 clamps and connect the 2 exhaust gas temperature sensor connectors.

      Tech Tips

      Make sure that the tape is in the position shown in the illustration.

  5. INSTALL FRONT PROPELLER SHAFT ASSEMBLY

    Click here

  6. INSTALL MONOLITHIC CONVERTER ASSEMBLY RH


    1. Install a new gasket to the turbocharger.

      Tech Tips

      Make sure that the claw of the gasket faces the transmission.

    2. A015D84E01

      Install the monolithic converter RH with 3 new nuts.

      Torque:
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }

    3. Temporarily install the manifold stay with the 3 bolts.

    4. Tighten the 2 bolts labeled A in the illustration first, and then tighten the bolt labeled B in the illustration.

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

    5. Attach the 4 clamps and connect the 2 exhaust gas temperature sensor connectors.

  7. INSTALL NO. 4 EXHAUST GAS TEMPERATURE SENSOR

    Note

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


    1. Using a 14 mm union nut wrench, install the 2 No. 4 exhaust gas temperature sensors.

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

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

      Tech Tips

      The identification tape on the exhaust gas temperature sensor is gold.

  8. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY


    1. Install a new gasket and the front No. 2 exhaust pipe to the monolithic converter LH with 3 new nuts.

      Torque:
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }
    2. A015B1SE01
      Text in Illustration
      *1 Tape
      *2 Stopper
      *3 Clip
      *a 2 to 7 mm (0.0787 to 0.276 in.)
      A015DSP Paint Mark

      Attach the clamp and connect the exhaust gas temperature sensor connector.

      Tech Tips

      Make sure that the tape is in the position shown in the illustration.

    3. Install 2 new clips to the 2 air hoses.

    4. Connect the 2 air hoses to the front No. 2 exhaust pipe.

      Note


      • Align the paint marks of the front No. 2 exhaust pipe and air hose and push on the 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 air hose when installing the clip.

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

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

  9. INSTALL NO. 5 EXHAUST PIPE ASSEMBLY


    1. Install a new gasket and the No. 5 exhaust pipe to the front No. 2 exhaust pipe with 2 new nuts.

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

  10. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. Install a new gasket and the front exhaust pipe to the monolithic converter RH with 3 new nuts.

      Torque:
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }
    2. A015CRKE01
      Text in Illustration
      *1 Tape
      *2 Stopper
      *3 Clip
      *a 2 to 7 mm (0.0787 to 0.276 in.)
      A015DSP Paint Mark

      Attach the clamp and connect the exhaust gas temperature sensor connector.

      Tech Tips

      Make sure that the tape is in the position shown in the illustration.

    3. Install 2 new clips to the 2 air hoses.

    4. Connect the 2 air hoses to the front exhaust pipe.

      Note


      • Align the paint marks of the front exhaust pipe and air hose and push on the 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 air hose when installing the clip.

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

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

  11. INSTALL CENTER EXHAUST PIPE ASSEMBLY


    1. A01585S

      Check the free length.


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

        Free length
        43 mm (1.69 in.)

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

    2. Connect the center exhaust pipe to the 3 exhaust pipe supports.

    3. Install 2 new gaskets to the No. 5 exhaust pipe and front exhaust pipe.

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

      Torque:
      for center exhaust pipe and front exhaust pipe
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
      for center exhaust pipe and No. 5 exhaust pipe
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }

  12. INSTALL TAILPIPE ASSEMBLY


    1. A015C0YE01
      Text in Illustration
      *1 Gasket
      *a Top
      *b LH Side
      A015DIT Front

      Connect the tailpipe to the 2 exhaust pipe supports.

    2. Install a new gasket to the center exhaust pipe.

    3. Connect the tailpipe to the center exhaust pipe with a new clamp.

      Tech Tips

      Install the clamp within the angle range shown in the illustration.

    4. Tighten the bolt.

      Torque:
      32 N*m  { 326 kgf*cm, 24 ft.*lbf }

  13. INSTALL AIR FUEL RATIO SENSOR

    Click here

  14. INSPECT FOR EXHAUST GAS LEAK

  15. INSTALL NO. 2 ENGINE UNDER COVER


    1. Install the No. 2 engine under cover with the 6 bolts.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

  16. INSTALL FRONT FENDER APRON SEAL REAR LH


    1. Install the front fender apron seal rear LH with the 4 clips.

  17. INSTALL FRONT FENDER APRON SEAL REAR RH


    1. Install the front fender apron seal rear RH with the 4 clips.

  18. PERFORM CATALYST RECORD OF DPF THERMAL DETERIORATION CLEAR FUNCTION

    Click here