Front Pipe Replacement 2.0L

Caution: Refer to Exhaust Service Caution in the Preface section.




1. Remove the splash guard. Refer to Engine Cover Replacement in Frame and Underbody.
2. Disconnect and remove the rear heated oxygen sensor. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 in Engine Controls-2.0L.
3. Remove the front exhaust pipe nuts and the gasket from the catalytic converter.



4. Remove the lower front exhaust pipe bracket.
5. Remove the front exhaust pipe from the upper front exhaust pipe mounting bracket.



6. Remove the front exhaust pipe from the rubber ring hangers near where the front exhaust pipe flange connects to the 3rd muffler flange.
7. Remove the nuts that secure the front exhaust pipe flange to the 3rd  muffler flange.
8. Remove the front exhaust pipe and the gasket.
9. Clean the sealing surfaces on the front exhaust pipe flange and the exhaust manifold.
10. Inspect the front exhaust pipe and the catalytic converter, or the 3rd muffler, for holes, damage, open seams, or other deterioration which could permit exhaust fumes to seep into the passenger compartment or the trunk.

1. Install the gasket between the 3rd muffler flange and the front muffler pipe flange.
2. Install the front muffler pipe.

Notice: Refer to Fastener Notice in the Preface section.

3. Install the nuts to secure the front muffler pipe to the 3rd muffler.

Tighten
Tighten the front muffler pipe to the 3rd muffler nuts to 30 N·m (22 lb ft).

4. Install the front exhaust pipe to the rubber ring hangers.



5. Install the front exhaust pipe into the upper front exhaust pipe mounting bracket.
6. Install the lower front exhaust pipe mounting bracket onto the front exhaust pipe.
7. Install the lower front exhaust pipe mounting bracket to the welded bolts of the upper front exhaust pipe mounting bracket using the nuts.

Tighten
Tighten the lower front exhaust pipe mounting bracket nuts to 30 N·m (22 lb ft).




8. Install the gasket between the front exhaust pipe flange and the catalytic converter.
9. Install the front exhaust pipe to the catalytic converter using the nuts.

Tighten
Tighten the front exhaust pipe-to-catalytic converter flange nuts to 40 N·m (30 lb ft).

Front Pipe Replacement 2.5L

Caution: Refer to Exhaust Service Caution in the Preface section.




1. Remove the exhaust lower bracket bolts.
2. Remove the exhaust lower bracket.
3. Remove the exhaust front pipe nuts and the gasket.



4. Remove the nuts that attach the exhaust front pipe to the exhaust front muffler.
5. Remove the gasket from the muffler.



6. Disconnect the exhaust front pipe from the rubber hanger.
7. Remove the exhaust front pipe.
8. Clean the sealing surfaces on the front muffler pipe flange and the exhaust front pipe.
9. Inspect the exhaust front pipe for holes, damage, open seams, or other deterioration which could permit exhaust fumes to seep into the passenger compartment.

Notice: Refer to Fastener Notice in the Preface section.




1. Install the exhaust front pipe and the gasket.
2. Connect the exhaust front pipe to the rubber hanger.



3. Install the exhaust front muffler to the exhaust front pipe.

Tighten
Tighten the nuts to 30 N·m (22 lb ft).




4. Install the gasket and the exhaust front pipe nuts.

Tighten
Tighten the nuts to 40 N·m (30 lb ft).

5. Install the exhaust lower bracket.
6. Install the exhaust lower bracket bolts.

Tighten
Tighten the bracket bolts to 40 N·m (30 lb ft).