EXHAUST PIPE (w/ DPF) INSTALLATION


  1. INSTALL CONVERTER PROTECTOR STAY


    1. Install the 2 No. 1 converter protector stays and 2 No. 2 converter protector stays to the front exhaust pipe.

  2. INSTALL MONOLITHIC CONVERTER PROTECTOR


    1. Install the upper monolithic converter protector and lower monolithic converter protector with the 4 bolts and 4 nuts.

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

  3. INSTALL EXHAUST PIPE CLAMP SUB-ASSEMBLY


    1. Install the exhaust pipe clamp with the bolt.

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

  4. INSTALL NO. 3 WIRING HARNESS CLAMP BRACKET


    1. Install the No. 3 wiring harness clamp bracket with the bolt.

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

  5. INSTALL NO. 3 EXHAUST GAS TEMPERATURE SENSOR

    A00JUMAE01
    Text in Illustration
    *1 Blue Tape

    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 blue.

    2. Attach the No. 3 exhaust gas temperature sensor wire harness.

  6. INSTALL NO. 2 EXHAUST GAS TEMPERATURE SENSOR

    A00JVIQE01
    Text in Illustration
    *A for Automatic Transmission
    *B for Manual Transmission
    *1 Yellow Tape
    *2 Red Tape

    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

      Refer to the illustration to identify the No. 2 exhaust gas temperature sensor being used.

  7. INSTALL EXHAUST GAS TEMPERATURE SENSOR

    A00JTXGE01
    Text in Illustration
    *1 Green Tape

    Note

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


    1. Using a 14 mm union nut wrench, install the 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 green.

  8. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. Install a new gasket and the front exhaust pipe to the No. 2 turbine outlet elbow with 3 new nuts.

      Torque:
      54 N*m  { 554 kgf*cm, 40 ft.*lbf }

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

      Tech Tips

      Install the exhaust pipe supports after installing the No. 3 frame crossmember.

    3. A00K10YE01
      Text in Illustration
      *1 Paint Mark
      *2 Stopper
      *3 Clip
      *a 4 to 10 mm (0.157 to 0.394 in.)

      Connect the No. 7 exhaust pipe air hose to the front exhaust pipe with a new clip.

      Note


      • Align the paint marks of the front exhaust pipe and No. 7 exhaust pipe air hose and insert the No. 7 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 No. 7 exhaust pipe air hose when installing the clip.

      • Make sure that there is no slack in the No. 7 exhaust pipe air hose, and that it is not twisted or bent.

      • Take care not to damage the inner or outer surface of the No. 7 exhaust pipe air hose when installing it. If the No. 7 exhaust pipe air hose is damaged, replace it with a new one.

    4. A00JUGKE01
      Text in Illustration
      *1 Paint Mark
      *2 Stopper
      *3 Clip
      *a 4 to 10 mm (0.157 to 0.394 in.)

      Connect the No. 6 exhaust pipe air hose to the front exhaust pipe with a new clip.

      Note


      • Align the paint marks of the front exhaust pipe and No. 6 exhaust pipe air hose and insert the No. 6 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 No. 6 exhaust pipe air hose, and that it is not twisted or bent.

      • Take care not to damage the inner or outer surface of the No. 6 exhaust pipe air hose when installing it. If the No. 6 exhaust pipe air hose is damaged, replace it with a new one.

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

    6. Connect the No. 2 exhaust gas temperature sensor connector.

    7. Connect the exhaust gas temperature sensor connector.

  9. INSTALL AIR FUEL RATIO SENSOR


    1. A00JWW9

      Disconnect the air fuel ratio sensor connector and detach the clamp.

    2. A00JTZJE01

      Using SST, remove the air fuel ratio sensor from the front exhaust pipe.

      SST
      09224-00010

  10. INSTALL NO. 3 EXHAUST PIPE SUPPORT BRACKET


    1. Install the No. 3 exhaust pipe support bracket with the 2 bolts.

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

  11. INSTALL NO. 2 EXHAUST PIPE SUPPORT BRACKET


    1. Install the No. 2 exhaust pipe support bracket with the 2 bolts.

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

  12. INSTALL NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY (for Manual Transmission)


    1. Install the No. 3 frame crossmember sub-assembly with the 4 bolts and 4 nuts.

      Torque:
      72 N*m  { 734 kgf*cm, 53 ft.*lbf }

    2. Install the 4 bolts to the No. 3 frame crossmember sub-assembly.

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

  13. INSTALL NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY (for Automatic Transmission)


    1. Install the frame crossmember to the rear engine mounting insulator with the 4 bolts.

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

    2. Install the frame crossmember with the 4 bolts and 4 nuts.

      Torque:
      72 N*m  { 734 kgf*cm, 53 ft.*lbf }

  14. INSTALL FRONT SUSPENSION MEMBER BRACKET LH AND RH (for Automatic Transmission)


    1. Install the front suspension member bracket LH and front suspension member bracket RH with the 8 bolts.

      Torque:
      33 N*m  { 337 kgf*cm, 24 ft.*lbf }

  15. INSTALL FRONT SUSPENSION MEMBER BRACKET RH (for Manual Transmission)


    1. Install the front suspension member bracket RH with the 4 bolts.

      Torque:
      33 N*m  { 337 kgf*cm, 24 ft.*lbf }

  16. INSTALL FRONT SUSPENSION MEMBER BRACKET LH (for Manual Transmission)


    1. Install the front suspension member bracket LH with the 4 bolts.

      Torque:
      33 N*m  { 337 kgf*cm, 24 ft.*lbf }

  17. INSTALL CENTER EXHAUST PIPE ASSEMBLY


    1. A00K1HV

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

      Minimum free length
      43 mm (1.693 in.)

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

    2. A00JTX1E11
      Text in Illustration
      *1 Gasket
      *2 Wooden Block

      Using a plastic-faced hammer and wooden block, tap in 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. for 3 Door:

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

    4. for 5 Door:


      1. Install the No. 1 exhaust pipe heat insulator with the nut.

        Torque:
        8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

      2. Install the exhaust pipe damper with the 2 bolts.

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

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

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

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

  18. INSTALL TAILPIPE ASSEMBLY


    1. Connect the tailpipe to the exhaust pipe support.

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

    3. Connect the tailpipe to the center exhaust pipe.

    4. Install the 2 bolts.

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

  19. INSPECT FOR EXHAUST GAS LEAK


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