EXHAUST SYSTEM REMOVAL/INSTALLATION [LF, L3]

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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.  Disconnect the negative battery cable.

2.  Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [L3].)

3.  Remove in the order indicated in the table.

4.  Install in the reverse order of removal.

Unleaded fuel model

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1
Main silencer
2
Middle pipe
3
TWC
(See TWC, Presilencer 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
HO2S (front)
(See HO2S Removal Note)
11
HO2S (rear)
(See HO2S Removal Note)

Leaded fuel model

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1
Main silencer
2
Presilencer
(See TWC, Presilencer Installation Note.)
3
Seal ring
(See Seal Ring Removal Note.)
(See Seal Ring Installation Note.)
4
Exhaust manifold insulator (upper)
(See Exhaust Manifold Insulator (Upper) Installation Note)
5
Bracket
(See Bracket Installation Note)
6
Exhaust manifold
(See Exhaust Manifold Installation Note)
7
Exhaust manifold gasket
8
Exhaust manifold insulator (lower)
(See Exhaust Manifold Insulator (Lower) Installation Note)


Seal Ring Removal Note

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

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HO2S Removal Note

1.  Remove the HO2S using the SST before removing the exhaust manifold.

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Exhaust Manifold Insulator (Lower) Installation Note

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

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2.  Verify that the insulator is installed as shown.

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Exhaust Manifold Installation Note

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

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Bracket Installation Note

1.  Temporarily tighten the exhaust manifold side bolts.

2.  Verify that the gap between the exhaust manifold and the bracket is 2.0—4.0 mm {0.08—0.16 in}.

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3.  Fully tighten the cylinder block side bolt.

Tightening torque
37.3—52.0 N·m {3.9—5.3 kgf·m, 27.6—38.3 ft·lbf}

4.  Fully tighten the exhaust manifold side bolts.

Tightening torque
40—55 N·m {4.1—5.6 kgf·m, 29.5—40.5 ft·lbf}


Exhaust Manifold Insulator (Upper) Installation Note

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

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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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TWC, Presilencer Installation Note

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

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

3.  Apply 1.0—2.5 g {0.036—0.088 oz} of grease (L3Z5 40 589) along the perimeter of the flared section.