#
EXHAUST SYSTEM REMOVAL/INSTALLATION [L3 4WD]

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  Warning

  • When the engine and exhaust system are hot, they can badly burn. Turn off the engine and wait until they are cool before removing the exhaust system.

1. Remove in the order indicated in the table.

2. Install in the reverse order of removal.

.

1 | Main silencer
2 | Presilencer
3 | TWC (See TWC Installation Note.)
4 | Seal ring (See Seal Ring Removal Note.) (See Seal Ring Installation Note.)
5 | Exhaust manifold insulator (upper) (See Exhaust Manifold Insulator (Upper) Installation Note.)
6 | Bracket (See Bracket Installation Note.)
7 | Exhaust manifold (See Exhaust Manifold Installation Note.)
8 | Exhaust manifold gasket
9 | Exhaust manifold insulator (lower) (See Exhaust Manifold Insulator (Lower) Installation Note.)
10 | A/F sensor (See A/F Sensor, HO2S Removal Note.)
11 | HO2S (See A/F Sensor, HO2S Removal Note.)

## Seal Ring Removal Note

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

## A/F Sensor, HO2S Removal Note

1. Using the SST, remove the A/F Sensor, HO2S.

## Exhaust Manifold Insulator (Lower) Installation Note

1. Tighten the exhaust manifold insulator (lower) installation bolts in the order shown.

2. Verify that there is 3.0-7.0 mm {0.12-0.27 in} gap between the exhaust manifold and the exhaust manifold insulator (lower).

## Exhaust Manifold Installation Note

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

## Bracket Installation Note

1. Temporarily tighten the bracket installation bolt by the side of the exhaust manifold.

2. Verify that there is 2.0-4.0 mm {0.08-0.15 in} gap between the exhaust manifold and the bracket.

3. Tighten the bracket installation bolt by the side of the cylinder block.

Tightening torque

  37.3-52.0 N·m {3.9-5.3 kgf·m, 27.6-38.3 ft·lbf}

4. Tighten the bracket installation bolt by the side of the exhaust manifold.

Tightening torque

  40-55 N·m {4.1-5.6 kgf·m, 30-40 ft·lbf}

## Exhaust Manifold Insulator (Upper) Installation Note

1. Tighten the exhaust manifold insulator (upper) installation bolts in the order shown.

## 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.

## TWC Installation Note

1. Spray carbon remover (TB6601 or equivalent) on the flared section of the exhaust pipe.

2. Remove the carbon adhering to the flared section shown in the figure using a nylon brush or sandpaper (No. 400 or equivalent).