EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5T]

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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.

Exhaust System Removal/Installation (2WD)

1. Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

2. Remove in the order indicated in the table.

3. Remove the insulator. (See Exhaust System Insulator Removal/Installation (2WD).)

4. Install in the reverse order of removal.

Step 1

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1	Main silencer
2	Plate (See Plate installation note (2WD).)
3	Brace bar (See Brace bar removal note (2WD).) (See Brace bar installation note (2WD).)
4	Tunnel member (See Tunnel member installation note (2WD).)
5	HO2S (See HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)
6	TWC

Step 2

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1	Insulator No.1 (See Insulator No.1 removal note (2WD).) (See Insulator No.1 installation note (2WD).)
2	A/F sensor (See AIR FUEL RATIO (A/F) SENSOR REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)
3	Insulator No.2 (See Insulator No.2 installation note (2WD).)
4	WU-TWC (See WU-TWC installation note (2WD).)
5	Insulator No.3
6	Dynamic pressure turbo (See DYNAMIC PRESSURE TURBO REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)
7	Exhaust manifold (See Exhaust manifold installation note (2WD).)

Brace bar removal note (2WD)

1. Remove the floor under cover. (See FLOOR UNDER COVER REMOVAL/INSTALLATION.)

2. Remove the brace bar.

Insulator No.1 removal note (2WD)

1. Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

2. Remove the cowl panel. (See COWL PANEL REMOVAL/INSTALLATION.)

3. Remove the front under cover No.2. (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)

4. Remove the front crossmember. (R.H.D.) (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)

5. Remove the insulator No.1.

Exhaust manifold installation note (2WD)

1. Tighten the nuts in the order shown in the figure.

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Tightening torque

45—52 N·m {4.6—5.5 kgf·m, 34—38 ft·lbf}

WU-TWC installation note (2WD)

1. Temporarily tighten the WU-TWC installation nuts.

2. Tighten the WU-TWC installation nuts in the order shown in the figure to the specified torque.

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Tightening torque

45—62 N·m {4.6—6.3 kgf·m, 34—45 ft·lbf}

3. Temporarily tighten the WU-TWC installation bolt.

4. Tighten the WU-TWC installation bolt to the specified torque.

Tightening torque

38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}

Insulator No.2 installation note (2WD)

1. Tighten the bolts in the order shown in the figure.

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Tightening torque

8—10 N·m {82—101 kgf·cm, 71—88 in·lbf}

Insulator No.1 installation note (2WD)

1. Install the insulator No.1.

2. Install the front under cover No.2. (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)

3. Install the cowl panel. (See COWL PANEL REMOVAL/INSTALLATION.)

4. Install the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

Tunnel member installation note (2WD)

1. Tighten bolt A shown in the figure to the specified torque.

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Tightening torque

18—26 N·m {1.9—2.6 kgf·m, 14—19 ft·lbf}

2. Tighten bolt B shown in the figure to the specified torque.

Tightening torque

18—26 N·m {1.9—2.6 kgf·m, 14—19 ft·lbf}

3. Tighten the remaining bolts to the specified torque.

Tightening torque

18—26 N·m {1.9—2.6 kgf·m, 14—19 ft·lbf}

Brace bar installation note (2WD)

1. Tighten bolt A shown in the figure to the specified torque.

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Tightening torque

18—26 N·m {1.9—2.6 kgf·m, 14—19 ft·lbf}

2. Tighten bolt B shown in the figure to the specified torque.

Tightening torque

18—26 N·m {1.9—2.6 kgf·m, 14—19 ft·lbf}

3. Tighten the remaining bolts to the specified torque.

Tightening torque

18—26 N·m {1.9—2.6 kgf·m, 14—19 ft·lbf}

4. Install the floor under cover. (See FLOOR UNDER COVER REMOVAL/INSTALLATION.)

Plate installation note (2WD)

1. Install fastener A shown in the figure.

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2. Install fastener B shown in the figure.

3. Install the remaining fasteners.

4. Tighten the bolts shown in the figure to the specified torque.

Tightening torque

9—12 N·m {92—122 kgf·cm, 80—106 in·lbf}

Exhaust System Insulator Removal/Installation (2WD)

1. Remove in the order indicated in the table.

2. Install in the reverse order of removal.

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1	Insulator (rear) (See Insulator (rear) removal note (2WD).) (See Insulator (rear) installation note (2WD).)
2	Insulator (middle) (See Insulator (middle) installation note (2WD).)
3	Insulator (front) (See Insulator (front) installation note (2WD).)

Insulator (rear) removal note (2WD)

Note

• The insulator (rear) are installed using rivets.

1. Push out the mandrel using a hammer and punch (2—2.8 mm {0.08—0.11 in} diameter).

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2. Remove the flange using a drill (5 mm {0.20 in} drill bit).

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Insulator (front) installation note (2WD)

1. Tighten nut A shown in the figure to the specified torque.

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Tightening torque

8—10 N·m {82—101 kgf·cm, 71—88 in·lbf}

2. Tighten nut B shown in the figure to the specified torque.

Tightening torque

8—10 N·m {82—101 kgf·cm, 71—88 in·lbf}

3. Tighten the remaining nuts to the specified torque.

Tightening torque

8—10 N·m {82—101 kgf·cm, 71—88 in·lbf}

Insulator (middle) installation note (2WD)

1. Tighten nut A shown in the figure to the specified torque.

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Tightening torque

8—10 N·m {82—101 kgf·cm, 71—88 in·lbf}

2. Tighten nut B shown in the figure to the specified torque.

Tightening torque

8—10 N·m {82—101 kgf·cm, 71—88 in·lbf}

3. Tighten the remaining nuts to the specified torque.

Tightening torque

8—10 N·m {82—101 kgf·cm, 71—88 in·lbf}

Insulator (rear) installation note (2WD)

1. Install rivets A shown in the figure.

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2. Install the remaining rivets.

Exhaust System Removal/Installation (4WD)

1. Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

2. Remove in the order indicated in the table.

3. Remove the insulator. (See Exhaust System Insulator Removal/Installation (4WD).)

4. Install in the reverse order of removal.

Step 1

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1	Main silencer
2	HO2S (See HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)
3	TWC

Step 2

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1	Insulator No.1 (See Insulator No.1 removal note (4WD).) (See Insulator No.1 installation note (4WD).)
2	A/F sensor (See AIR FUEL RATIO (A/F) SENSOR REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)
3	Insulator No.2 (See Insulator No.2 installation note (4WD).)
4	WU-TWC (See WU-TWC installation note (4WD).)
5	Insulator No.3
6	Dynamic pressure turbo (See DYNAMIC PRESSURE TURBO REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)
7	Exhaust manifold (See Exhaust manifold installation note (4WD).)

Insulator No.1 removal note (4WD)

1. Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

2. Remove the cowl panel. (See COWL PANEL REMOVAL/INSTALLATION.)

3. Remove the front crossmember. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)

4. Remove the insulator No.1.

Exhaust manifold installation note (4WD)

1. Tighten the nuts in the order shown in the figure.

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Tightening torque

45—52 N·m {4.6—5.5 kgf·m, 34—38 ft·lbf}

WU-TWC installation note (4WD)

1. Temporarily tighten the WU-TWC installation nuts.

2. Tighten the WU-TWC installation nuts in the order shown in the figure to the specified torque.

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Tightening torque

45—62 N·m {4.6—6.3 kgf·m, 34—45 ft·lbf}

3. Temporarily tighten the WU-TWC installation bolt.

4. Tighten the WU-TWC installation bolt to the specified torque.

Tightening torque

38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}

Insulator No.2 installation note (4WD)

1. Tighten the bolts in the order shown in the figure.

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Tightening torque

8—10 N·m {82—101 kgf·cm, 71—88 in·lbf}

Insulator No.1 installation note (4WD)

1. Install the insulator No.1.

2. Install the front crossmember. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)

3. Install the cowl panel. (See COWL PANEL REMOVAL/INSTALLATION.)

4. Install the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

Exhaust System Insulator Removal/Installation (4WD)

1. Remove the propeller shaft. (See PROPELLER SHAFT REMOVAL/INSTALLATION.)

2. Remove in the order indicated in the table.

3. Install in the reverse order of removal.

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1	Insulator (rear) (See Insulator (rear) removal note (4WD).) (See Insulator (rear) installation note (4WD).)
2	Insulator (middle) (See Insulator (middle) installation note (4WD).)
3	Insulator (front) (See Insulator (front) installation note (4WD).)

Insulator (rear) removal note (4WD)

Note

• The insulator (rear) are installed using rivets.

1. Push out the mandrel using a hammer and punch (2—2.8 mm {0.08—0.11 in} diameter).

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2. Remove the flange using a drill (5 mm {0.20 in} drill bit).

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Insulator (front) installation note (4WD)

1. Tighten nut A shown in the figure to the specified torque.

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Tightening torque

8—10 N·m {82—101 kgf·cm, 71—88 in·lbf}

2. Tighten nut B shown in the figure to the specified torque.

Tightening torque

8—10 N·m {82—101 kgf·cm, 71—88 in·lbf}

3. Tighten the remaining nuts to the specified torque.

Tightening torque

8—10 N·m {82—101 kgf·cm, 71—88 in·lbf}

Insulator (middle) installation note (4WD)

1. Tighten nut A shown in the figure to the specified torque.

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Tightening torque

8—10 N·m {82—101 kgf·cm, 71—88 in·lbf}

2. Tighten nut B shown in the figure to the specified torque.

Tightening torque

8—10 N·m {82—101 kgf·cm, 71—88 in·lbf}

3. Tighten the remaining nut to the specified torque.

Tightening torque

8—10 N·m {82—101 kgf·cm, 71—88 in·lbf}

Insulator (rear) installation note (4WD)

1. Install rivets A shown in the figure.

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2. Install the remaining rivets.