Exhaust System: Service and Repair

Exhaust Outlet Replacement

Removal Procedure





1. Raise the vehicle. Refer to Vehicle Lifting.
2. Remove the exhaust manifold pipe to exhaust outlet clamp.





3. Remove the exhaust manifold pipe to catalytic pipe flange bolts.
4. Slide the exhaust manifold pipe hanger from the insulator.





5. Remove the exhaust pipe from the vehicle.
6. It equipped with an automatic transmission, remove the transmission fluid fill tube to bell housing nuts.
7. Position the transmission fluid fill tube to the right side of the vehicle. The tube does not require removal from the transmission.





8. Remove the 3 bolts (1) retaining the right exhaust pipe to the exhaust manifold.





9. Remove the lower bolt (2) retaining the heat shield to the exhaust outlet.
10. Lower the vehicle.





11. Move the hood to the service position by moving the hood hinge bolts (1) to the service positions (2).





12. Remove the upper intake manifold sight shield using the following procedure:
12.1. Remove the retaining bolt in the front of the shield.
12.2. Lift-up on the front of the shield.
12.3. Lift the shield off the rear bracket.





13. Remove the 3 bolts holding the heat shield to the turbocharger.
14. Remove the turbocharger heat shield.





15. Remove the remaining 2 bolts (1, 3) for the exhaust outlet heat shield.
16. Remove the exhaust outlet heat shield.





17. Remove the exhaust outlet 4 bolts and the 2 nuts.
18. Remove the exhaust outlet and gasket from the turbocharger.
19. Position the exhaust outlet to the side in order to access the right exhaust pipe to turbocharger bolts.
The exhaust outlet cannot be removed until the right exhaust pipe is removed.





20. Remove the 3 bolts (2) from the right exhaust pipe to the turbocharger.
21. Remove the right exhaust pipe and gaskets.
22. Remove the exhaust outlet out the bottom of the vehicle.





23. Clean the exhaust outlet.
24. Clean the exhaust outlet and turbocharger mating surfaces.
25. Inspect the exhaust outlet for dents and cracks.
26. Replace the exhaust outlet if any damage is found.

Installation Procedure





1. From under the vehicle, position the exhaust outlet to rear of the engine Do not install the outlet to the turbocharger.
2. Install the right exhaust pipe with NEW gasket to the turbocharger. Align the tabs on the gasket to face inward.

Notice: Refer to Fastener Notice in Service Precautions.

3. Install the exhaust pipe to turbocharger bolts (2).
^ Tighten the exhaust pipe to turbocharger bolts to 53 Nm (39 ft. lbs.).





4. Install the exhaust outlet with a NEW gasket to the turbocharger.
5. Install the exhaust outlet bolts and nuts.
^ Tighten the exhaust outlet 4 bolts and 2 nuts to 53 Nm (39 ft. lbs.)





6. Install the exhaust outlet heat shield.
7. Install the upper 2 exhaust outlet heat shield bolts (1, 3).
^ Tighten the exhaust outlet heat shield bolts to 8 Nm (71 inch lbs.).





8. Install the turbocharger heat shield.
9. Install the turbocharger heat shield bolts.
^ Tighten the turbocharger heat shield bolts to 9 Nm (80 inch lbs.).





10. Raise the vehicle.
11. Install the lower bolt (2) for the exhaust outlet heat shield.
^ Tighten the exhaust outlet heat shield bolt to 8 Nm (71 inch lbs.).





12. If equipped with an automatic transmission, install the transmission fluid fill tube to bell housing nuts.
^ Tighten the transmission fluid fill tube nuts 18 Nm (13 ft. lbs.).





13. Install the right exhaust pipe to the exhaust manifold with a NEW gasket. Align the tab on the gasket to face outward as shown.
14. Install the right exhaust pipe to exhaust manifold bolts (1).
^ Tighten the exhaust pipe to exhaust manifold bolts to 53 Nm (39 ft. lbs.).





15. Install the exhaust manifold pipe hanger in the insulator.
16. Install the exhaust manifold pipe to the exhaust muffler pipe.
17. Install the exhaust manifold pipe bolts.
^ Tighten the exhaust manifold pipe bolts 40 Nm (30 ft. lbs.).





18. Install the exhaust outlet to exhaust manifold pipe clamp. Ensure the exhaust manifold pipe is square to the exhaust outlet.
^ Tighten the exhaust manifold pipe clamp to 40 Nm (30 ft. lbs.).
19. Lower the vehicle.





20. Install the upper intake manifold sight shield.
^ Tighten the upper intake manifold shield bolt to 9 Nm (80 inch lbs.).





21. Position the hood in the normal operating position by moving the hood hinge bolts from service position (2) to normal operating position (1).
^ Tighten the hood hinge bolts to 25 Nm (18 ft. lbs.).
22. Inspect for exhaust leaks.