Front Pipe Replacement 2.0L

1. On California 2.0L engine, remove 5 upper exhaust manifold heat shield bolts.
2. Remove the upper exhaust manifold heat shield.



3. Remove 3 exhaust manifold to front pipe nuts (1).
4. On all, raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
5. On California 2.0L engine, remove the heated oxygen sensor (HO2S) 2. Refer to Heated Oxygen Sensor 2 Replacement in Engine Controls-2.0L.



6. Remove 1 bolt and 1 nut from the exhaust manifold pipe bracket.



7. On all, remove 2 bolts and the front pipe/TWC assembly (2) from the exhaust manifold (1).



8. On non-California 2.0L engine, remove the electrical connector at the heated oxygen sensor (H02S2) (6).



9. On all, remove two nuts and the front pipe/TWC assembly (1) from the resonator/muffler/tail pipe assembly.
10. Remove the hanger supporting the TWC.
11. Remove the front pipe/TWC assembly (1) from the vehicle.
12. Clean the gasket and the seal mating surfaces.

Important: When installing a new exhaust system component, always use new gaskets and seals.

1. On all, install the front pipe/TWC assembly to the vehicle.
2. Support the TWC with a hanger.
3. Attach the front pipe/TWC assembly with a new gasket to the resonator/muffler/tail pipe assembly.
4. Secure the resonator/muffler/tail pipe assembly with 2 nuts. Do not fully tighten the nuts.



5. On non-California 2.0L engine, attach the electrical connector to the heated oxygen sensor (H02S2) (6).
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.




7. 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).

8. Install the heated oxygen sensor (HO2S) 2. Refer to Heated Oxygen Sensor 2 Replacement in Engine Controls-2.0L.
9. 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).

10. 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).

11. On all, lower the vehicle.



12. 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).

13. Position exhaust manifold upper heat shield to the exhaust manifold.
14. Install 5 exhaust manifold upper heat shield bolts.