EXHAUST SYSTEM REMOVAL/INSTALLATION [ZY]

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Warning

• A hot engine and exhaust system can cause severe burns. Turn off the engine and wait until they are cool before removing the exhaust system.

1. Disconnect the negative battery cable.

2. Before the engine coolant hose, remove the engine coolant. (See ENGINE COOLANT REPLACEMENT [ZY].)

3. Remove in the order indicated in the table.

4. Install in the reverse order of removal.

5. Inspect the front wheel alignment and adjust it if necessary. (See FRONT WHEEL ALIGNMENT.)


1	Main silencer
2	Crossmember
3	Member
4	TWC
5	Seal ring (See Seal Ring Removal Note.) (See Seal Ring Installation Note.)
6	Front HO2S (See FRONT HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [ZY].)
7	Rear HO2S (See REAR HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [ZY].)
8	EGR cooler (See EGR COOLER REMOVAL/INSTALLATION [ZY].)
9	Engine coolant hose (See ENGINE COOLANT REPLACEMENT [ZY].)
10	EGR pipe (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [ZY].)
11	EGR valve assembly (See EGR valve assembly Removal Note.)
12	Exhaust manifold insulator (See Exhaust Manifold/Exhaust Manifold Insulator Removal Note.)
13	Exhaust manifold (See Exhaust Manifold/Exhaust Manifold Insulator Removal Note.) (See Exhaust Manifold Installation Note.)

Seal Ring Removal Note

1. Remove the seal ring using a flathead screwdriver being careful not to damage the pipe.

Exhaust Manifold/Exhaust Manifold Insulator Removal Note

Note

• When removing the exhaust manifold, move the exhaust manifold insulator slightly out of the way, loosen the nuts, then remove the exhaust manifold together with the insulator. Refer to the following procedure.

1. Remove the front wheels and tires.

2. Disconnect the steering shaft from the steering gear and linkage side. (See STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION.)

3. Remove the No.1 engine mount rubber. (See ENGINE REMOVAL/INSTALLATION [ZY].)

4. Loosen the exhaust manifold insulator bolts.

5. Move the exhaust manifold insulator slightly out of the way and loosen the exhaust manifold nuts.

6. Remove the front stabilizer and stabilizer control link installation bolt.

7. Remove the front crossmember (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)

8. Remove the exhaust manifold together with the insulator by lowering it to the underside of the vehicle.

EGR valve assembly Removal Note

1. Remove the following parts for easier access.

• Remove the air cleaner cover and the air cleaner case. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [ZY].)

Exhaust Manifold Installation Note

1. Tighten the exhaust manifold installation nuts in the order shown in the figure.

Seal Ring Installation Note

Caution

• If installation is performed without using the SST, the seal ring will be damaged and deformed, resulting in an incorrect installation. Always use the SST to install the seal ring.

1. Temporarily install the seal ring to the pipe so that the seal ring is even with the flange.

2. Install the SST to the seal ring so that the SST is even with the flange.

3. Press in the seal ring by tapping the SST using a plastic hammer until the seal ring contacts the flange.