EXHAUST SYSTEM REMOVAL/INSTALLATION [L3]

id0115a2800200

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. Remove in the order indicated in the table.

2. Install in the reverse order of removal.

R.H.D. model


1	After-silencer
2	Main silencer
3	HO2S (See HO2S Removal Note.)
4	Catalytic converter
5	Seal ring (See Seal Ring Removal Note (R.H.D.).) (See Seal Ring Installation Note (R.H.D.).)
6	Exhaust manifold (See Exhaust Manifold Insulator, Exhaust Manifold Removal Note (R.H.D.).) (See Exhaust Manifold, Exhaust Manifold Insulator Installation Note (R.H.D.).)
7	Exhaust manifold insulator (See Exhaust Manifold Insulator, Exhaust Manifold Removal Note (R.H.D.).) (See Exhaust Manifold, Exhaust Manifold Insulator Installation Note (R.H.D.).)

L.H.D. model


1	After-silencer
2	Main silencer
3	Presilencer
4	Front pipe
5	Exhaust manifold insulator (See Exhaust Manifold, Exhaust Manifold Insulator Installation Note (L.H.D.).)
6	Exhaust manifold (See Exhaust Manifold, Exhaust Manifold Insulator Installation Note (L.H.D.).)
7	Front HO2S (See HO2S Removal Note.)
8	Rear HO2S (See HO2S Removal Note.)

HO2S Removal Note

1. Remove the HO2S using the SST.

Seal Ring Removal Note (R.H.D.)

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

Front Pipe Removal Note

1. Remove the transverse member. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)

2. Remove the splash shield.

3. Remove the under cover.

4. Remove the front pipe.

Exhaust Manifold Insulator, Exhaust Manifold Removal Note (R.H.D.)

Note

• When removing the exhaust manifold, refer to the following procedure, loosen the bolts while positioning the exhaust manifold insulator out of the way, then remove.

1. Loosen the exhaust manifold insulator bolts.

2. Position the generator out of the way, then position the exhaust manifold insulator out of the way. (See GENERATOR REMOVAL/INSTALLATION [L3 R.H.D.].)

3. Loosen the exhaust manifold nuts and bolts.

4. Lower the exhaust manifold.

5. Remove the exhaust manifold insulator.

Exhaust Manifold, Exhaust Manifold Insulator Installation Note (R.H.D.)

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

Exhaust manifold installation bolt tightening torque

43-64 N·m {4.4-6.5 kgf·m, 32-47 ft·lbf}

2. Tighten the exhaust manifold bracket and exhaust manifold insulator installation bolts in the order shown in the figure.

Exhaust manifold bracket installation bolts tightening torque

1: 37.3-52 N·m {3.8-5.3 kgf·m, 28-38 ft·lbf}

2, 3: 46-55 N·m {4.7-5.6 kgf·m, 34-40 ft·lbf}

Exhaust manifold insulator installation bolts tightening torque

7.8-10.8 N·m {80-110 kgf·cm, 69-95 in·lbf}

Exhaust Manifold, Exhaust Manifold Insulator Installation Note (L.H.D.)

1. Temporarily install and lightly tighten the exhaust manifold to the exhaust manifold bracket.

2. Tighten the exhaust manifold installation bolts in the order shown in the figure.

Exhaust manifold installation bolt tightening torque

43-64 N·m {4.4-6.5 kgf·m, 32-47 ft·lbf}

3. Tighten the exhaust manifold bracket installation bolts and nuts.

Seal Ring Installation Note (R.H.D.)

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.