For 1990-2009 cars

## Front Pipe Replacement 2.0L Diesel

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

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

Caution: 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 and tighten the front pipe nuts to 40 N·m (29.5 lb ft).

## Front Pipe Replacement 2.4L

### Removal Procedure

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

1. Disconnect the negative battery cable.
2. Remove the engine under cover.
3. Remove the rear heated oxygen sensor connector.
4. Remove the pup converter-to-exhaust front pipe retaining nuts.
5. Remove the exhaust front pipe mounting bracket bolt and nut.
6. Remove the nuts from the exhaust front pipe-to-underbody catalytic converter (UCC).
7. Disconnect the exhaust front pipe from the rubber hanger.
8. Remove the exhaust front pipe and the gasket.
9. Clean the sealing surfaces on the UCC flange and the exhaust front pipe.
10. Check 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. Secure the exhaust front pipe to the rubber hanger.

Caution: Refer to Fastener Caution in the Preface section.

2. Install the nuts and gasket to the exhaust front pipe-to-UCC and tighten to 30 N·m (22 lb ft).
3. Install the pup converter and the gasket to the exhaust front pipe flange and tighten.

• | The pup converter-to-exhaust front pipe retaining nuts to 40 N·m (30 lb ft).

• | The exhaust front pipe mounting bracket bolt and nut to 40 N·m (30 lb ft).

4. Connect the rear heated oxygen sensor connector.
5. Install the engine under cover.
6. Connect the negative battery cable.

## Front Pipe Replacement 3.2L

### Removal Procedure

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

1. Disconnect the negative battery cable.
2. Remove the engine under cover.
3. Disconnect the lower heated oxygen sensor connector bank 2.
4. Disconnect the lower heated oxygen sensor connector back 1.
5. Remove the exhaust from pipe support bracket retaining bolt from the oil pan.
6. Remove the pup converter-to-exhaust front pipe retaining nuts at bank 1 and bank 2.
7. Remove the pup converter-to-exhaust front pipe gasket.
8. Remove the 3 nuts from the exhaust front pipe-to-underbody catalytic converter (UCC).
9. Remove the exhaust front pipe-to-UCC gasket.
10. Remove the exhaust front pipe.
11. Clean the sealing surfaces on the UCC flange and exhaust front pipe.
12. Check 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

Caution: Refer to Fastener Caution in the Preface section.

1. Install the exhaust front pipe-to-UCC retaining 3 nuts and gaskets and tighten the retaining nuts to 30 N·m (22 lb ft).
2. Install the pup converter-to-exhaust front pipe flange nuts with the gaskets at bank 1 and bank 2 and tighten the retaining nuts to 40 N·m (30 lb ft).
3. Install the exhaust front pipe support bracket bolts to the oil pan and tighten the retaining bolts to 40 N·m (30 lb ft).
4. Connect the lower heated oxygen sensor connectors.
5. Install the engine under cover.
6. Connect the negative battery cable.