Exhaust Pipe: Service and Repair

Removal & Installation and Disassembly & Reassembly
1. DISCONNECT BATTERY NEGATIVE TERMINAL
2. REMOVE FRONT DOOR SCUFF PLATE RH (4WD DRIVE TYPE)





a) Using a screwdriver, remove the front door scuff plate RH.

HINT: Tape the screwdriver tip before use.

3. REMOVE COWL SIDE TRIM BOARD RH (4WD DRIVE TYPE)





a) Remove the clip and cowl side trim board.
4. REMOVE REAR DOOR SCUFF PLATE RH (4WD DRIVE TYPE)





a) Using a screwdriver, remove the rear door scuff plate RH.

HINT: Tape the screwdriver tip before use.

5. REMOVE CENTER PILLAR GARNISH LOWER RH (4WD DRIVE TYPE)





a) Using a screwdriver, remove the center pillar garnish lower RH.

HINT: Tape the screwdriver tip before use.

6. REMOVE FRONT SEAT ASSEMBLY RH (4WD DRIVE TYPE)
7. REMOVE HEATED OXYGEN SENSOR (2WD DRIVE TYPE)





a) Using a clip remover, remove the clip.
b) Pull off the floor carpet front.





c) Disconnect the heated oxygen sensor connector.
d) Remove the grommet, then pull the connector to the outside of the vehicle.





e) Using SST, remove the heated oxygen sensor.
8. REMOVE HEATED OXYGEN SENSOR (4WD DRIVE TYPE)





a) Remove the heated oxygen sensor connector as shown in the illustration.





b) Using SST, remove the heated oxygen sensor.
SST 09224-00010
9. REMOVE EXHAUST PIPE ASSEMBLY TAIL (2WD DRIVE TYPE)
a) Remove the tail pipe assembly with 2 bolts and 2 springs.
10. REMOVE EXHAUST PIPE ASSEMBLY TAIL (4WD DRIVE TYPE)
a) Remove the bolt and clamp.
b) Remove the tail pipe and gasket.
11. REMOVE EXHAUST PIPE ASSEMBLY CENTER (4WD DRIVE TYPE)
a) Remove the exhaust pipe assembly center with 2 bolts and 2 springs.
12. REMOVE FLOOR PANEL BRACE FRONT (2WD DRIVE TYPE)





a) Remove the 2 nuts and floor panel brace front.
13. REMOVE EXHAUST PIPE ASSEMBLY FRONT
a) Remove the exhaust pipe front.
14. INSTALL EXHAUST PIPE ASSEMBLY FRONT
a) Check the free length.





1) Using vernier calipers, measure the free length of the compression spring.
Minimum length: 41.5 mm (1.6339 inch)

HINT: If the free length is less than minimum, replace the compression spring.





b) Using a wooden block and plastic-faced hammer, tap a new gasket in until it is flush with the exhaust manifold.

NOTICE:
^ Make sure that the gasket is installed in the right direction.
^ Do not reuse the removed gasket.
^ Never push the gasket into the exhaust manifold by installing the exhaust pipe front onto the exhaust manifold.

c) Install the exhaust pipe front onto the 2 exhaust pipe supports No. 4.
d) Tighten the 2 compression springs and 2 bolts.
Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.)
15. INSTALL FLOOR PANEL BRACE FRONT (2WD DRIVE TYPE)





a) Install the floor panel brace front with 2 nuts.
Torque: 30 Nm (302 kgf-cm, 22 ft. lbs.)
16. INSTALL EXHAUST PIPE ASSEMBLY CENTER (4WD DRIVE TYPE)
a) Check the free length.





1) Using vernier calipers, measure the free length of the compression spring.
Minimum: 38.5 mm (1.5158 inch)
If the free length is less than minimum, replace the compression spring.





b) Install a new gasket onto the exhaust pipe front.

NOTICE:
^ Make sure that the gasket is installed in the right direction.
^ Do not reuse the removed gasket.
^ Never push the gasket into the exhaust pipe front by installing the exhaust pipe center onto the exhaust pipe front.

c) Install the exhaust pipe front onto the 2 exhaust pipe sup ports No. 4.
d) Tighten the 2 compression springs and 2 bolts.
Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.)
17. INSTALL EXHAUST PIPE ASSEMBLY TAIL (2WD DRIVE TYPE)
a) Check the free length.





1) Using vernier calipers, measure the free length of the compression spring.
Minimum: 38.5 mm (1.5158 inch)
If the free length is less than minimum, replace the compression spring.





b) Install a new gasket onto the exhaust pipe front.

NOTICE:
^ Make sure that the gasket is installed in the right direction.
^ Do not reuse the removed gasket.
^ Never push the gasket into the exhaust pipe front by installing the exhaust pipe tail onto the exhaust pipe front.

c) Install the exhaust pipe tail onto the 3 exhaust pipe supports No. 4.
d) Tighten the 2 compression springs and 2 bolts.
Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.)
18. INSTALL EXHAUST PIPE ASSEMBLY TAIL (4WD DRIVE TYPE)





a) Install the tail pipe assembly with a bolt as shown in the illustration.
Torque: 32 Nm (330 kgf-cm, 24 ft. lbs.)
19. INSTALL HEATED OXYGEN SENSOR








a) Using SST, install the heated oxygen sensor.
SST 09224-00010
Torque: 44 Nm (450 kgf-cm, 33 ft. lbs.)
b) Connect the heated oxygen sensor connector.

HINT: After installing the heated oxygen sensor, check that sensor wire is not twisted. If it is twisted, remove the heated oxygen sensor and reinstall it.

20. CONNECT BATTERY NEGATIVE TERMINAL
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
21. CHECK FOR EXHAUST GAS LEAKAGE
22. INSTALL FRONT SEAT ASSEMBLY RH (4WD DRIVE TYPE)