EXHAUST SYSTEM REMOVAL/INSTALLATION [ZJ, 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. (See BATTERY REMOVAL/INSTALLATION [ZJ, ZY].)

2.  Remove in the order indicated in the table.

3.  Install in the reverse order of removal.

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1	Main silencer
2	Tunnel member
3	Middle pipe
	Presilencer
4	Seal ring (See Seal Ring Removal Note.) (See Seal Ring Installation Note.)
5	A/F sensor (See AIR FUEL RATIO (A/F) SENSOR REMOVAL/INSTALLATION [ZJ, ZY].)
6	HO2S (See HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [ZJ, ZY].)
7	Exhaust manifold insulator (See Exhaust Manifold Insulator Removal Note.)
8	Exhaust manifold (See Exhaust Manifold Removal Note.) (See Exhaust Manifold Installation Note.)
9	WU-TWC bracket

Exhaust System Insulator

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Seal Ring Removal Note

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

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Exhaust Manifold Insulator Removal Note

1.  Remove the air cleaner cover. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [ZJ, ZY].)

2.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [ZJ, ZY].)

3.  Remove the EGR pipe (exhaust manifold side). (See EGR PIPE REMOVAL/INSTALLATION [ZJ, ZY].)

4.  Remove the cowl grille. (See COWL GRILLE REMOVAL/INSTALLATION.)

5.  Remove the windshield wiper arm and blade. (See WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION.)

6.  Remove the cowl panel. (See COWL PANEL REMOVAL/INSTALLATION.)

7.  Remove the windshield wiper motor. (See WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION.)

8.  Remove the exhaust manifold insulator.

Exhaust Manifold Removal Note

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

2.  Remove the cylinder head side fitting bolts of the catalytic converter component bracket.

3.  Remove the exhaust manifold and the catalytic converter component bracket as a single unit.

4.  Remove the WU-TWC bracket from exhaust manifold.

Exhaust Manifold Installation Note

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

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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.

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

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

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