Exhaust Y-Pipe - Van/Wagon
Exhaust Y-Pipe - Van/WagonSpecial Tool(s):
Material:
Removal and Installation
WARNING: The normal operating temperature of the exhaust system is very high. Never attempt to service any part of the system until it has cooled. Be especially careful when working around the catalytic converter. The temperature of the catalytic converter rises to a high level after only a few minutes of engine operation. Failure to follow these instructions may result in personal injury.
CAUTION: Do not use oil or grease-based lubricants on the isolators. These lubricants may cause deterioration of the rubber. This can lead to separation of the isolator from the exhaust hanger bracket during vehicle operation.
NOTE: Exhaust fasteners are of a prevailing torque design. Use only new fasteners with the same part number as the original. Torque values must be used as specified during reassembly to make sure of correct retention of exhaust components.
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair.
2. Remove the engine cover.
3. Disconnect the heated oxygen sensors and the catalyst monitor sensor electrical connectors.
4. Support the muffler and tailpipe assembly and exhaust intermediate pipe with a safety stand.
5. Release the exhaust intermediate pipe and the front muffler and tailpipe hanger isolators.
6. NOTE: New Torca(R) clamps must be installed when loosened.
Loosen the exhaust intermediate pipe-to-exhaust Y-pipe Torca(R) clamp nut and release the tension on the clamp.
^ To install, tighten to 55 Nm (41 ft. lbs).
7. Remove the exhaust intermediate pipe and the muffler and tailpipe from the exhaust Y-pipe.
8. NOTE: LH shown, RH similar.
Remove the 2 LH and 1 RH heat shield-to-crossmember bolts.
^ To install, tighten to 10 Nm (89 inch lbs).
9. Remove the 2 crossmember-to-rear transmission mount nuts.
^ To install, tighten to 95 Nm (70 ft. lbs).
10. Support the rear of the transmission with a safety stand.
11. NOTE: RH shown, LH similar.
Remove the RH and LH transmission crossmember-to-frame nuts and bolts and remove the transmission crossmember.
^ To install, tighten to 81 Nm (60 ft. lbs).
12. Remove the 4 exhaust Y-pipe-to-exhaust manifold nuts and discard. Remove the exhaust Y-pipe.
^ To install, tighten the upper exhaust Y-pipe-to-exhaust manifold nuts to 40 Nm (30 ft. lbs.) then tighten the lower exhaust Y-pipe-to-exhaust manifold nuts to 40 Nm (30 ft. lbs).
13. If reusing the exhaust intermediate pipe, note the orientation of the Torca(R) clamp, grind the spot weld and remove the old Torca(R) clamp.
14. If installing new catalytic converters, remove the heated oxygen sensors (HO2S) and the catalyst monitor sensors.
^ Apply a light coat of high temperature nickel anti-seize lubricant to the HO2S and catalyst monitor sensor threads prior to installation.
^ To install, tighten to 46 Nm (34 ft. lbs).
15. To install, reverse the removal procedure.
^ If reusing the exhaust intermediate pipe, install a new Torca(R) clamp in the same orientation as the original and spot weld into place.