For 1990-2009 cars

## Front Pipe Replacement Gasoline Engines

### Removal Procedure

1. Remove the crossmember lower bracket with the bolts.
2. Disconnect the oxygen sensor connector.
3. Remove the exhaust front pipe mounting bracket bolt.
4. Remove the nuts from the exhaust front pipe-to-catalytic converter flange.
5. Remove the nuts from the exhaust front pipe-to-exhaust front muffler.
6. Remove the exhaust front pipe and the gasket.
7. Clean the sealing surfaces on the exhaust front muffler pipe flange and the exhaust front pipe.
8. Inspect the exhaust front pipe for holes, damage, open seams or other deterioration which could permit exhaust fumes to seep into the passenger compartment.

### Installation Procedure

1. Install the exhaust front pipe and the gasket.

Notice: Refer to Fastener Notice in the Preface section.

2. Install the nuts from the exhaust front pipe-to-exhaust front muffler.

Tighten
Tighten the exhaust front pipe-to-exhaust front muffler nets to 30 N·m (22 lb ft).

3. Install the nuts from the exhaust front pipe-to-catalytic converter flange.
4. Install the exhaust front pipe mounting bracket bolt.

#### Tighten

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

• | Tighten the exhaust front pipe-to-cylinder block bolt to 50 N·m (37 lb ft).

5. Connect the oxygen sensor connector.
6. Install the crossmember lower bracket bolts.

Tighten
Tighten the crossmember lower bracket bolts to 35 N·m (26 lb ft).

## Front Pipe Replacement Diesel Engine

### Removal Procedure

Caution: Refer to Battery Disconnect Caution in the Preface section.

Caution: In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.

Notice: When inspecting or replacing exhaust system components, make sure there is adequate clearance from all points on the underbody to prevent overheating of the floor pan and possible damage to the passenger compartment insulation and trim materials.

1. Disconnect the negative battery cable.
2. Disconnect the exhaust gas temperature sensor 1 connector.
3. Remove the rubber hanger.
4. Remove the exhaust front pipe with the gasket. If damaged, replace the new gasket.

### Installation Procedure

Notice: Refer to Fastener Notice in the Preface section.

1. Install the exhaust front pipe.

Tighten
Tighten the exhaust front pipe nuts to 40 N·m (29.5 lb ft).

2. Install the rubber hanger.
3. Connect the exhaust gas temperature sensor/connector.
4. Connect the negative battery cables.