Exhaust System: Service and Repair

Exhaust System Replacement (Gasoline)

Removal Procedure

Warning

In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.

Warning

Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges from worn exhaust components could result in serious personal injury.

1. Remove the exhaust rear muffler. Refer to Exhaust Rear Muffler Replacement Service and Repair.





Note: A second technician is required.

2. Remove the 4 exhaust pipe front hanger bracket bolts (4, 5).
3. Remove the 2 exhaust pipe front hanger bracket insulator nuts (3).
4. Remove the exhaust pipe front hanger bracket (2).
5. Remove the 2 exhaust pipe front hanger bracket insulators (1).





Note: A second technician is required.

6. Remove the heated oxygen sensor (1).
7. Remove and DISCARD the 3 catalytic converter nuts (3).
8. Remove the exhaust front pipe gasket (4) from the catalytic converter and exhaust front pipe (2).
9. Remove the exhaust system.

Installation Procedure

Note: A second technician is required.

1. Install the exhaust system.




2. Install the NEW exhaust front pipe gasket (4).

Caution: Refer to Fastener Caution Fastener Caution.

Caution: Refer to Torque-to-Yield Fastener Caution Torque-to-Yield Fastener Caution.

3. Install the 3 NEW catalytic converter nuts (3) to the exhaust front pipe (2) and tighten to 22 Nm (16 lb ft).
4. Install the heated oxygen sensor (1) and tighten to 42 Nm (31 lb ft).




5. Install the 2 exhaust pipe front hanger bracket insulators (1).
6. Install the exhaust pipe front hanger bracket (2).
7. Install the 2 exhaust pipe front hanger bracket insulator nuts (3) and tighten to 17 Nm (13 lb ft).
8. Install the 4 exhaust pipe front hanger bracket bolts (4, 5) and tighten to 22 Nm (16 lb ft).
9. Install the 2 exhaust pipe front hanger bolts (5) - M10 and tighten to 60 Nm (44 lb ft).
10. Install the exhaust rear muffler. Refer to Exhaust Rear Muffler Replacement Service and Repair.