B. Repair Procedure
Tools Required for Repair10mm, 12mm deep sockets (3/8" drive), and 14mm deep socket (1/2" drive)
Ratchet (3/8" drive and 1/2" drive)
Extensions - 6" & 10" (3/8" drive and 1/2" drive)
Pry bar
Small standard screwdriver
Diagonal Cutter
Scissors
Utility knife
Spring loaded center punch
1/4" metal drill bit
1/4" Nut Driver
Round "Rat Tail" file (small)
Mirror
Drop light or flashlight
Torque wrench (ft-lbf)
Safety Goggles
Power drill
Wood boring bit (3/4") (purchase locally at hardware store)
Additional Materials Required
WD-40 (or equivalent thread loosener)
Masking tape
Permatex Thread locker # 27140 (or equivalent)
ValuGard Rust Preventative (see Parts Information)
WARNING:
^ A hot engine and exhaust system can cause severe burns. Turn off the engine and wait until cool before removing the exhaust system.
^ When drilling holes on the vehicle body from under the vehicle, always wear protective glasses to prevent metal debris from getting into your eyes.
NOTE:
Follow all other necessary precautions to ensure a safe working environment.
Summary of Repair Procedure
1. Replace main silencer heat insulator, front insulator, and main silencer with modified parts.
2. To install main silencer heat insulator, a new bracket must be installed on the vehicle body.
3. Check A/C drain grommet for heat damage. If any damage is found, replace A/C drain grommet with new part.
4. Remove tie wrap bands on harness of the 02 sensor and fastener. These are used only on production and not needed.
5. Reprogram PCM.
KITS CONTENTS
1. Main silencer heat insulator kit part no. CCY3-56-40X
2. Front heat insulator kit part no. CCY3-56-400A
3. Main silencer kit part no. L3Z2-40-SAO
Exhaust System Overview
Inspection for Warning Label
NOTE:
A vehicle sold to a customer would not have the warning label.
1. Inspect gear shift console for presence of a Warning Label since some inventory vehicles may have it.
- If warning label is present, remove and discard. Proceed to "REMOVAL PROCEDURE".
- If warning label is not present, proceed to "REMOVAL PROCEDURE".
REMOVAL PROCEDURE
WARNING:
Be sure to wear protective glasses to prevent debris from getting into your eyes.
1. Open the lift gate.
2. Fold the third-row seatback forward.
3. Open and fold back the trunk board over the third-row seat backs. Remove the cargo sub-compartment.
4. Remove the jack cover, then remove the jack. Be careful not to scratch surrounding panels.
5. Lift up the vehicle on a hoist.
6. Remove and discard the two (2) 14mm nuts and springs from the pre-silencer and main silencer flange at the rear of vehicle. Spray WD-40 (or equivalent) to threads for easier nut removal.
7. Remove three (3) rubber hangers from the main silencer using a prybar.
8. Remove the main silencer.
CAUTION:
To prevent the main silencer from falling off suddenly, it is recommended to have another person assist.
NOTE:
Be careful not to damage seal ring while removing main silencer because it will be reused. If any damage exists, replace with part no. Z501-40-581A.
9. Remove the two (2) gray rubber hangers from the vehicle body by twisting 90 degrees left or right. Remove the one (1) black rubber hanger.
10. Discard the three (3) rubber hangers.
11. Remove the main silencer heat insulator by removing three (3) 10mm nuts and one (1) 10mm bolt.
12. Remove the front and rear tunnel members by removing eight (8) 12mm bolts.
13. Remove the front cross member by removing one (1) 10mm bolt, and four (4) 14mm bolts.
14. Remove and discard the two (2) 14mm pre-silencer flange nuts. Spray WD-40 (or equivalent) to threads for easier nut removal. Remove and discard gasket.
15. Remove two (2) pre-silencer rubber hangers using a prybar.
CAUTION:
To prevent the pre-silencer from falling off suddenly, it is recommended to have another person assist.
16. Remove pre-silencer.
NOTE:
^ When removing pre-silencer from rubber hangers, be careful not to damage the rubber hangers because they will be reused. If any damage exists, replace with part no. Z601-40-061B.
^ Be careful not to over bend the exhaust flexible pipe while removing pre-silencer. Over bending the flexible pipe could cause damage resulting in failure.
17. Remove the pre-silencer insulator by removing four (4) 10mm nuts.
18. Remove and discard the two (2) fasteners, two (2) plastic nuts, and front insulator.
19. Using diagonal cutters, cut off two (2) tie wrap bands on the 02 sensor harness.
NOTE:
Be careful not to damage the harness.
20. Remove one (1) plastic pin. Discard the tie wrap bands and plastic pin, they will not be needed.
A/C Grommet Inspection
21. Check condition of NC drain grommet.
- If any damage is found, proceed to "A/C Drain Hose Replacement" in next step.
- If not, proceed to "INSTALLATION PROCEDURES".
22. Lower vehicle.
23. Remove right side trim from center console by pulling up from bottom.
24. Remove clip from upper drain hose, and replace A/C drain hose assembly (which includes grommet) with part no. BP4K-61-526.
25. Fit grommet to vehicle body and fasten clip to heater unit.
26. Reinstall right side trim.
INSTALLATION PROCEDURES
WARNING:
Be sure to wear protective glasses to prevent metal debris from getting into your eyes.
Main Silencer Heat Insulator Installation Procedure (Use kit part no. CCY3-56-40X)
1. Obtain paper template part no. CCY3-56-G11 from repair kit and cut pattern paper along the line labeled "CUT,.
2. Lift vehicle up.
3. Position template at the left rear of vehicle by locating holes (i.e.: sunroof drain grommet and body stamp) and side of quarter pillar as a reference mark. Affix with masking tape.
4. Put a mark in the center of the hole with a center punch (two locations).
5. Drill hole using a 1/4 inch drill bit (two locations). When done, remove template and discard.
6. Deburr the two (2) 1/4 inch newly drilled holes using a small round file.
7. Lower vehicle to access jack storage compartment from inside vehicle cabin. Using 3/4" wood boring bit and nut driver, remove damping sheet material around the newly drilled holes. This eliminates soft material between the bolt and vehicle body to prevent bolts from loosening.
NOTE:
^ Be sure to turn the 3/4" wood boring bit by hand, in order to prevent drilling a hole in the body. Use a vacuum cleaner or tape to remove debris from inside the cabin.
8. Apply VALUGARD Rust Preventative to the holes. Be sure to coat any exposed metal.
NOTE:
Shake can at least one minute.
9. Insert two (2) new bolts (part no. 99465-0616) in new holes.
10. Lift vehicle up.
11. Spray additional rust preventative at exposed metal only. Be sure to keep bolt threads clean.
12. Install new bracket (part no. C235-56-D20) to vehicle body. Be sure threaded holes face inward, toward middle of vehicle.
13. Apply Permatex Threadlocker # 27140 (or equivalent) to two (2) new nuts (part no. 99940-0603). Install nuts to bolts to hold bracket.
14. Lower vehicle.
15. With assistant, tighten nuts to bolts.
Tightening torque: 8.0 - 11.0 N-m (0.9 - 1.1 kgf-m, 5.9 - 8.1 ft-lbf)
16. From inside vehicle, apply VALUGARD Rust Preventative around the bolts and holes. This will provide sealing to prevent outside moisture from entering into vehicle cabin.
17. Lift vehicle up.
18. Apply VALUGARD Rust Preventative around the nuts and holes. This will provide sealing to prevent outside moisture from entering into vehicle cabin.
NOTE:
Rust preventative should be allowed to dry for at least 30 minutes.
19. Install modified heat insulator (part no. C235-56-450) to the vehicle body and new bracket using two (2) new bolts (part no. 99465-0616) and existing three (3) 10mm nuts and one (1) 10mm bolt.
Front Heat Insulator Installation Procedure (Use front heat insulator kit part no. CCY3-56-400A)
20. Insert right end of modified front insulator (part no. C235-56-442B) inside metal tab and fasten with two (2) new plastic nuts (part no. B100-68-615) and two (2) new fasteners (part no. GJ6A-68-885).
21. Install original pre-silencer heat insulator using existing four (4) 10mm nuts.
22. With an assistant helping to hold the original pre-silencer, fasten pre-silencer to vehicle body with existing two (2) rubber hangers. Spray WD-40 in hangers to make installation easier.
23. Install pre-silencer to exhaust flexible pipe using new gasket (part no. LFO7-40-305A) and two (2) 14mm new nuts (part no. 9YB0-041-017).
Tightening torque: 38 - 51 N-m (3.9 - 5.2 kgf-m, 29 - 37 ft-lbf)
24. Install front cross member with original 10mm bolt and four (4) l4mm bolts.
Tightening torque (10mm bolt): 7.8 - 10.8 N-m (0.80- 1.10 kgf-m, 5.8 - 8.0 ft-lbf) Tightening torque (14mm bolts): 36.3 - 53.9 N-m (3.71 - 5.49 kgf-m, 26.8 - 39.7 ft-lbf)
25. Install the front and rear tunnel members with eight (8) l2mm bolts.
NOTE:
Be sure that arrow points toward front of vehicle.
Main Silencer Installation Procedure (Use Main silencer kit part no. L3Z2-40-SA0)
26. Fasten modified main silencer (part no. L388-40-100B) to vehicle body using three (3) new rubber hangers (part nos. LF07-40-061B and BP47-40-061A). Spray WD-40 in hangers to make installation easier.
27. Connect main silencer to pre-silencer with new springs (part no. YJ15-40-582) and new nuts (9YB0-41-015).
28. Perform a final inspection to be sure each part is secured and tightened properly.
29. Lower vehicle.
30. Re-install jack, jack cover, and cargo sub-compartment.
31. Place trunk board and third row seat backs in their original positions.
PCM Reprogramming
32. Reboot the WDS PTU to clear memory before reprogramming.
33. Using WDS B39.8 or later software, reprogram the PCM to the latest calibration (refer to "Calibration Information" table) by following the "Module Reprogramming" procedure.
NOTE:
^ Always update the WDS PTU first, then install the needed calibration file that WDS shows during PCM reprogramming. Go to "WDS Calibration" on ESI and download the "update" file. If the PTU is not updated to the latest WDS calibration level, the calibration file will not install into the PTU.
^ It is not necessary to remove any fuses or relays during PCM reprogramming when the WDS screen prompts you to do so. You may accidentally stop power to one of the PCM terminals and cause the PCM to be blanked, or you may receive error messages during the WDS reprogramming procedure.
^ WDS shows the calibration part numbers after programming the PCM.
^ Please be aware that PCM calibration part numbers and file names listed in any Service Bulletin may change due to future releases of WDS software, and additional revisions made to those calibrations for service related concerns.
^ When reprogramming a PCM, WDS will always display the "latest" calibration P/N available for that vehicle. If any calibration has been revised/updated to contain new information for a new service concern/issue, it will also contain all previously released calibrations.
^ When performing this procedure, if the WDS PTU is not docked and connected to 115V-120V, we recommend that a battery charger be installed on the vehicle battery and turned ON to a maximum charge of no more than 20 AMPS to keep the vehicle battery up to capacity. If you exceed 20 AMPS, it will damage the WDS PTU. Also the external battery power supply cable should be connected to the vehicle battery and the PTU.
34. After performing the PCM reprogramming procedure, verify the repair by starting the engine and making sure there are no MIL illumination or abnormal warning lights present.
NOTE:
^ If any DTCs should remain after performing DTC erase, diagnose the DTCs according to the appropriate Troubleshooting section of the Workshop Manual.
^ After PCM reprogramming, it is no longer necessary to road test the vehicle to "relearn" KAM (Keep Alive Memory).
35. Place a "Campaign" label (P/N 9999-95-065A-05) with the new calibration information on the bulkhead by right strut tower. (Labels are available through MStore).
36. Start vehicle and let idle for 60 seconds. Inspect for any exhaust leaks and repair as needed. Be sure the check engine light (MIL) turns OFF.
37. Return vehicle to customer.
CALIBRATION INFORMATION
PART(S) INFORMATION