Exhaust System: Service and Repair

Exhaust System Replacement

Removal Procedure

Special Tools

CH-6614 - Chain Pipe Cutter

For equivalent regional tools, refer to Special Tools Tools and Equipment.

Warning: Refer to Protective Goggles and Glove Warning Protective Goggles and Glove Warning


Warning: Refer to Exhaust Service Warning Service Precautions.


1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair




2. Cut the exhaust rear muffler (2) with the CH-6614 - pipe cutterat position (1).




3. Remove the rear exhaust muffler (2) from the exhaust isolators (1).

4. Sand smooth the front exhaust pipe for ease of installation.

5. Remove the exhaust rear muffler.




6. Remove the exhaust front pipe fasteners (1) and discard the gasket (2).

7. Remove the 3-way catalytic converter (4) from the exhaust isolators (3).




8. Lower the intermediate exhaust front muffler pipe (5).

9. Remove and transfer the catalytic converter, if necessary.

Installation Procedure




1. Install the exhaust rear muffler (2) into the exhaust isolators (1).




2. Install the intermediate exhaust front muffler (5) to the front exhaust hanger isolators (2).





Caution: Refer to Fastener Caution Fastener Caution.

3. Install the 3-way catalytic converter (4) into the exhaust Isolators (3) with a NEW gasket (2) and tighten the fasteners (1) to 17 Nm (13 lb ft).




4. Install the new rear exhaust muffler (2) into the exhaust isolators.

5. Lower the vehicle.

6. Start the engine and check for exhaust leaks.




7. Position the exhaust front pipe (3) into the exhaust muffler clamp.

Note: There are 3 different exhaust muffler clamps depending on the diameter of the exhaust pipe.

8. Install the rear exhaust muffler (2) into the exhaust muffler clamp and tighten the bolt (1) to 50 Nm (37 lb ft).

9. Lower the vehicle.

10. Start the engine and check for exhaust leaks.