Front Pipe Replacement 2.5L
Removal Procedure
- Disconnect the Heated Oxygen Sensor (HO2S1) electrical connectors and
detach the couplers from the coupler mounting bracket.
- Raise and support the vehicle. Refer to
Lifting and Jacking the Vehicle
in General Information.
- Remove the propeller shaft. Refer to
Front Propeller Shaft Replacement
.
- Remove the 2 bolts (1) from
the front pipe assembly (2).
- Remove the 6 front pipe nuts (1)
from the exhaust manifolds (2).
- Remove the front pipe and the exhaust manifold gaskets.
Installation Procedure
Important: When installing a new exhaust system component,
always use new gaskets and seals.
- Position the front pipe with new exhaust manifold gaskets.
- Install the 6 front pipe nuts (1)
to the exhaust manifolds (2). Do not fully tighten the nuts.
- Install the 2 bolts (1)
to the front pipe assembly (2). Do not fully tighten the bolts.
- Install the propeller shaft. Refer to
Front Propeller Shaft Replacement
.
- Align all system components before tightening the fasteners, in order
to prevent noise or vibrations.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or
corrosion inhibitors on fasteners or fastener joint surfaces unless specified.
These coatings affect fastener torque and joint clamping force and may damage
the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.
- Tighten the front pipe assembly bolts.
Tighten
Tighten the front pipe assembly bolts to 50 N·m
(37 lb ft).
- Tighten the front pipe assembly nuts.
Tighten
Tighten the front pipe assembly nuts to 50 N·m
(37 lb ft).
- Lower the vehicle.
- Connect the Heated Oxygen Sensor (HO2S1) electrical connectors and attach
the couplers to the coupler mounting bracket.
Front Pipe Replacement 2.0L
Removal Procedure
- On California 2.0L engine, remove 5 upper exhaust manifold heat shield
bolts.
- Remove the upper exhaust manifold heat shield.
- Remove 3 exhaust manifold to front pipe
nuts (1).
- On all, raise and support the vehicle. Refer to
Lifting and Jacking the Vehicle
in General Information.
- On California 2.0L engine, remove the heated oxygen sensor (HO2S) 2. Refer
to
Heated Oxygen Sensor 2 Replacement
in Engine Controls-2.0L.
- Remove 1 bolt and 1 nut from the exhaust
manifold pipe bracket.
- On all, remove 2 bolts and the front pipe/TWC
assembly (2) from the exhaust manifold (1).
- On
non-California 2.0L engine, remove the electrical connector at the heated oxygen sensor
(H02S2) (6).
- On all, remove two nuts and the front pipe/TWC
assembly (1) from the resonator/muffler/tail pipe assembly.
- Remove the hanger supporting the TWC.
- Remove the front pipe/TWC assembly (1) from the vehicle.
- Clean the gasket and the seal mating surfaces.
Installation Procedure
Important: When installing a new exhaust system component,
always use new gaskets and seals.
- On all, install the front pipe/TWC assembly to the vehicle.
- Support the TWC with a hanger.
- Attach the front pipe/TWC assembly with a new gasket to the resonator/muffler/tail
pipe assembly.
- Secure the resonator/muffler/tail pipe assembly with 2 nuts. Do not
fully tighten the nuts.
- On
non-California 2.0L engine, attach the electrical connector to the heated oxygen sensor
(H02S2) (6).
- On all, connect the front pipe/TWC assembly, with a new seal, to the exhaust
manifold and secure with 2 bolts. Do not fully tighten the bolts.
Notice: Refer to Fastener Notice in the Preface section.
- On California 2.0L engine, install 1 bolt and 1 nut to the exhaust manifold
pipe bracket.
Tighten
Tighten the front exhaust pipe bracket nut and bolt
to 50 N·m (37 lb ft).
- Install the heated oxygen sensor (HO2S) 2. Refer to
Heated Oxygen Sensor 2 Replacement
in Engine Controls-2.0L.
- On non-California engines, align all system components before tightening
the fasteners, in order to prevent noise or vibrations.
Tighten
• | Tighten the front pipe/TWC assembly-to-exhaust manifold bolts to 50 N·m
(37 lb ft). |
• | Tighten the front pipe/TWC assembly-to-resonator/muffler/tail pipe assembly
nuts to 35 N·m (26 lb ft). |
- On California 2.0L engine, align all system components before tightening
the fasteners, in order to prevent noise or vibrations.
Tighten
Tighten the front pipe/TWC assembly-to-resonator/muffler/tail
pipe assembly nuts to 35 N·m (26 lb ft).
- On all, lower the vehicle.
- On California 2.0L engine, install 3 exhaust
manifold to front pipe nuts (1).
Tighten
Tighten the front pipe assembly-to-exhaust manifold
bolts to 50 N·m (37 lb ft).
- Position exhaust manifold upper heat shield to the exhaust manifold.
- Install 5 exhaust manifold upper heat shield bolts.