For 1990-2009 cars

## Exhaust System Replacement 2L Diesel LLW

#### Special Tools

CH-6614 Chain-Type Pipe Cutter

For equivalent regional tools, refer to Special Tools.

### Removal Procedure

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

Warning: Refer to Protective Goggles and Glove Warning in the Preface section.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Cut the exhaust rear muffler (2) with CH-6614 cutter (1).
3. Remove the exhaust rear muffler (3) from the exhaust rear muffler hanger insulator (1, 2).
4. Remove the exhaust flex pipe. Refer to Exhaust Flexible Pipe Replacement.
5. Remove the exhaust particulate filter. Refer to Exhaust Particulate Filter Replacement.
6. Remove all hanger insulators from the exhaust pipe and underbody.

### Installation Procedure

1. Install all hanger insulators at the exhaust pipe and underbody.
2. Install the exhaust particulate filter. Refer to Exhaust Particulate Filter Replacement.
3. Install the exhaust flex pipe. Refer to Exhaust Flexible Pipe Replacement.
4. Install the exhaust rear muffler (3) at the exhaust rear muffler hanger insulator (2, 4).

Caution: Refer to Fastener Caution in the Preface section.

5. Install the exhaust pipe clamp (1) and tighten to XX N·m(XX lb ft).

## Exhaust System Replacement 1.6L LXV

#### Special Tools

CH 6614 Chain Pipe Cutter

For equivalent regional tools, refer to Special Tools.

### Removal Procedure

1. Raise the vehicle by its full height. Refer to Lifting and Jacking the Vehicle.

Warning: While engine is operating, the exhaust system will become extremely hot. To prevent burns avoid contacting a hot exhaust system.

2. Make a cut and disconnect the CH 6614 cutter at position (1).

Note: A second person is required.

3. Hang out the exhaust rear muffler (3) from the exhaust rear muffler insulator (1, 2).
4. Remove the exhaust rear muffler.

Note: A second person is required.

5. Remove the 4 exhaust pipe front hanger bracket bolts (2, 4).
6. Remove the 2 exhaust pipe front hanger bracket insulator nuts (3).
7. Remove the exhaust pipe front hanger bracket (1).

Note: A second person is required.

8. Disconnect the heated oxygen sensor wiring harness plug (1).
9. Remove the 3 catalytic converter to exhaust pipe (2) nuts (3).
10. Remove the catalytic converter to exhaust to exhaust pipe gasket (4).
11. Remove the exhaust system.

### Installation Procedure

Warning: While engine is operating, the exhaust system will become extremely hot. To prevent burns avoid contacting a hot exhaust system.

Note: A second person is required.

1. Install the exhaust system.
2. Install the NEW catalytic converter to exhaust pipe gasket (4).

Caution: Refer to Fastener Caution in the Preface section.

3. Install the 3 NEW catalytic converter to exhaust pipe (2) nuts (3) and tighten to 20 N·m (15 lb ft).
4. Connect the heated oxygen sensor wiring harness plug (1).
5. Install the exhaust pipe front hanger bracket (1).
6. Install the 2 exhaust pipe front hanger bracket insulator nuts (3) and tighten to 20 N·m (15 lb ft).
7. Install the 4 exhaust pipe front hanger bracket bolts (2, 4) and tighten to 25 N·m (19 lb ft).

Note: A second person is required.

8. Install the exhaust rear muffler.
9. Hang in the exhaust rear muffler (3) at position (2, 4).

Note: Use a NEW exhaust pipe clamp.

10. Connect the exhaust rear muffler with the muffler through a exhaust pipe clamp at position (1) and tighten the clamp to 20 N·m (15 lb ft).
11. Lower the vehicle by its full height.