Exhaust System: Service and Repair
EXHAUST SYSTEM REMOVAL/INSTALLATION [L3 WITH TC]Warning:
^ A hot engine and exhaust system can cause severe burns. Turn off the engine and wait until they are cool before removing the exhaust system.
1. Disconnect the negative battery cable.
2. Remove the charge air cooler duct.
3. Remove the charge air cooler cover.
4. Remove the charge air cooler.
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.
Seal Ring Removal Note
1. Remove the seal ring using a flathead screwdriver being careful not to damage the pipe.
H02S Removal Note
1. Remove the H02S using the SST before removing the exhaust manifold.
Exhaust Manifold Insulator (Upper) Removal Note
1. Remove the charge air cooler bracket.
2. Remove the exhaust manifold insulator (upper)
WU-TWC Removal Note
2WD
1. Remove the generator duct.
2. Remove the WU-TWC.
4WD
1. Remove the cowl grille.
2. Remove the windshield wiper motor.
3. Remove the cowl panel.
4. Remove the generator duct.
5. Set the generator out of the way.
6. Remove the WU-TWC.
Exhaust Manifold Installation Note
1. Tighten the exhaust manifold installation nuts in the order shown.
Tightening torque 43 - 64 Nm (4.4 - 6.5 kgf.m, 32 - 47 ft.lbf)
WU-TWC Installation Note
1. Temporarily tighten No.1 shown in the figure.
2. Temporarily tighten No.2 shown in the figure.
3. Temporarily tighten No.3 shown in the figure.
4. Completely tighten No.1 shown in the figure.
Tightening torque 38 - 51 Nm (3.9 - 5.2 kgf.m, 29 - 37 ft.lbf)
5. Completely tighten No.2 shown in the figure.
Tightening torque 38 - 51 Nm (3.9 - 5.2 kgf.m, 29 - 37 ft.lbf)
6. Completely tighten No.3 shown in the figure.
Tightening torque 38 - 51 Nm (3.9 - 5.2 kgf.m, 29 - 37 ft.lbf)
Seal Ring Installation Note
Caution:
^ If installation is performed without using the SST, the seal ring will be damaged and deformed, resulting in an incorrect installation. Always use the SST to install the seal ring.
1. Temporarily install the seal ring to the pipe so that the seal ring is even with the flange.
2. Install the SST to the seal ring so that the SST is even with the flange.
3. Press in the seal ring by tapping the SST using a plastic hammer until the seal ring contacts the flange.