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. Remove the battery cover. Removal and Replacement
2. Disconnect the negative battery cable. Removal and Replacement
3. Remove in the order indicated in the table.
4. Remove the exhaust system insulator.
5. Install in the reverse order of removal.
Exhaust System Insulator Removal/installation Note
1. Remove the exhaust system insulator in the order shown in the figure.
2. Install in the reverse order of removal.
Insulator (Rear No.1, No.2, No.3) Removal Note
NOTE:
- The insulator (rear No.1, No.2, No.3) are installed using rivets.
1. Push out the mandrel using a hammer and punch (2-2.8 mm {0.08-0.11 in} diameter).
2. Remove the flange using a drill (5 mm {0.20 in} drill bit).
Insulator (Front) Removal Note
1. Remove the tunnel member (front).
2. Remove the insulator (front).
Seal Ring Removal Note
1. Remove the seal ring using a flathead screwdriver being careful not to damage the pipe.
Exhaust Manifold Upper Insulator Removal Note
1. Remove the charge air cooler cover. Service and Repair
2. Remove the charge air cooler. Service and Repair
3. Remove the charge air cooler bracket. Service and Repair
4. Remove the exhaust manifold upper insulator.
WU-TWC Insulator Removal Note
1. Remove the turbocharger insulator. Service and Repair
2. Remove the WU-TWC insulator.
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 (WU-TWC Side) 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.
TWC Installation Note
1. Spray carbon remover (TB6601 or equivalent) on the flared section of the exhaust pipe.
2. Remove the carbon adhering to the flared section shown in the figure using a nylon brush or sandpaper (No. 400 or equivalent).
Seal Ring (TWC Side) 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.
Presilencer Installation Note
1. Spray carbon remover (TB6601 or equivalent) on the flared section of the exhaust pipe.
2. Remove the carbon adhering to the flared section shown in the figure using a nylon brush or sandpaper (No. 400 or equivalent).