Exhaust Pipe: Service and Repair

Exhaust Pipe

Turbo model:

STI model:

Turbo model:

STI model:

2. Front Exhaust Pipe
REMOVAL
1. Disconnect the ground cable from battery.
2. Remove the front oxygen (A/F) sensor.
3. Remove the under cover.
4. Remove the lower exhaust manifold cover (RH).
5. Remove the lower and upper exhaust manifold covers (I-H).

6. Remove the bolts and nuts which hold the front exhaust pipe assembly to turbocharger joint pipe.
7. While holding the front exhaust pipe assembly with one hand, remove the nuts which hold the front exhaust pipe assembly to cylinder head exhaust port.

8. Remove the front exhaust pipe assembly.
9. Remove the covers from exhaust manifold and front exhaust pipe.
10. Separate the front exhaust pipe from exhaust manifolds.
^ Turbo model

^ STI model

INSTALLATION

NOTE: Replace the gaskets with new ones.

1. Assemble the front exhaust pipe and exhaust manifolds.
Tightening torque: 35 Nm (3.6 kgf-m, 26 ft. lbs.)
^ Turbo model

^ STI model

2. Install the front exhaust pipe covers.
Tightening torque:
Turbo model 7.5 Nm (0.8 kgf-m, 5.5 ft. lbs.)
STI model 25 Nm (2.5 kgf-m, 18.1 ft. lbs.)
3. Install the upper exhaust manifold cover (RH).
Tightening torque:
Turbo model 7.5 Nm (0.8 kgf-m, 5.5 ft. lbs.)
STI model 19 Nm (1. 9 kgf-m, 13.7 ft. lbs.)
4. Install the front exhaust pipe assembly.
Tightening torque: 35 Nm (3.6 kgf-m, 26 ft. lbs.)
5. Connect the exhaust manifold (RH) to turbocharger joint pipe.
^ Turbo model
Tightening torque:
T1: 35 Nm (3.6 kgf-m, 26 ft. lbs.)
T2: 40 Nm (4 kgf-m, 28.9 ft. lbs.)

^ STI model
Tightening torque: 35 Nm (3.6 kgf-m, 26 ft. lbs.)

6. Install the upper and lower exhaust manifold covers (LH).
Tightening torque:
Turbo model 7.5 Nm (0.8 kgf-m, 5.5 ft. lbs.)
STI model 19 Nm (1.9 kgf-m, 13.7 ft. lbs.)
7. Install the lower exhaust manifold cover (RH).
Tightening torque:
Turbo model 7.5 Nm (0.8 kgf-m, 5.5 ft. lbs.)
STI model 19 Nm (1.9 kgf-m, 13.7 ft. lbs.)

8. Install the front oxygen (A/F) sensor.
9. Install the under cover.
10. Connect the battery ground cable to battery.

3. Center Exhaust Pipe
REMOVAL
1. Set the vehicle on a lift.
2. Disconnect the ground cable from battery.
3. Remove the intercooler.
4. Remove the intercooler bracket.

5. Lift-up the vehicle.
6. Remove the under cover.
7. Remove the bolts which install the under side of turbocharger lower cover.

CAUTION: Be careful, the turbocharger and exhaust pipe are hot.

8. Lower the vehicle.
9. Remove the turbocharger upper cover.

10. Remove the bolts which install the upper side of turbocharger lower cover, and remove it.

11. Separate the center exhaust pipe from turbocharger.

12. Lift-up the vehicle.
13. Disconnect the connector from rear oxygen sensor.

14. Vertically draw out the clip from crossmember.

15. Separate the center exhaust pipe from rear exhaust pipe.

16. Remove the bolt which holds the center exhaust pipe bracket to transmission.

17. Remove the intercooler bracket.
18. Remove the bolt which holds the center exhaust pipe to hanger bracket.

CAUTION: Be careful not to pull down the center exhaust pipe.

19. Remove the center exhaust pipe.

INSTALLATION

NOTE: Replace the gaskets with new ones.

1. Install the center exhaust pipe and temporarily tighten the bolt which holds the center exhaust pipe to hanger bracket.
2. Temporarily tighten the bolt which holds the center pipe to transmission.
3. Connect the center exhaust pipe to turbocharger.
Tightening torque: 35 Nm (3.6 kgf-m, 26 ft. lbs.)

4. Install the center exhaust pipe to rear exhaust pipe.
Tightening torque: 18 Nm (1.8 kgf-m, 13 ft. lbs.)

5. Connect the connector to rear oxygen sensor.

6. Secure the clip on crossmember.

7. Tighten the bolt which holds the center exhaust pipe bracket to transmission.
Tightening torque: 30 Nm (3.1 kgf-m, 22.4 ft. lbs.)

8. Tighten the bolt which holds the center exhaust pipe to hanger bracket.
Tightening torque: 35 Nm (3.6 kgf-m, 26 ft. lbs.)

9. Lower the vehicle.
10. Place the turbocharger lower cover, and tighten the bolts which install the upper side of lower cover.
Tightening torque: 7.5 Nm (0.8 kgf-m, 5.5 ft. lbs.)

11. Place the turbocharger upper cover, and tighten the bolts which install the upper side of upper cover.
Tightening torque: 7.5 Nm (0.8 kgf-m, 5.5 ft. lbs.)

12. Lift-up the vehicle.
13. Tighten the bolts which install the under side of turbocharger lower cover.
Tightening torque: 7.5 Nm (0.8 kgf-m, 5.5 ft. lbs.)

14. Install the under cover.
15. Lower the vehicle.
16. Install the intercooler bracket.

17. Install the intercooler.

4. Joint Pipe
REMOVAL
1. Disconnect the ground cable from battery.
2. Remove the front oxygen (A/F) sensor.
3. Remove the under cover.
4. Remove the exhaust manifold lower cover (RH).

5. Remove the nuts which hold the front exhaust manifold to joint pipe.

6. Remove the center exhaust pipe.
7. Remove the turbocharger.
8. Take off the joint pipe in the upward direction.

INSTALLATION
Install in the reverse order of removal.
Tightening torque:
T. 35 Nm (3.6 kgf-m, 26 ft. lbs.)

5. Rear Exhaust Pipe
REMOVAL
1. Disconnect the ground cable from battery.
2. Lift-up the vehicle.
3. Separate the rear exhaust pipe from center exhaust pipe.

CAUTION: Be careful, the exhaust pipe is hot.

4. Separate the rear exhaust pipe from muffler.

CAUTION: Be careful not to pull down the rear exhaust pipe.

5. Remove the rear exhaust pipe.

INSTALLATION

NOTE: Replace the gaskets and self-locking nut with new ones.

1. Install the rear exhaust pipe to muffler.
Tightening torque: 48 Nm (4.9 kgf-m, 35.4 ft. lbs.)

2. Install the rear exhaust pipe to center exhaust pipe.
Tightening torque: 18 Nm (1.8 kgf-m, 13 ft. lbs.)

3. Lower the vehicle.
4. Connect the battery ground cable to battery.

INSPECTION
1. Make sure there are no exhaust leaks from connections and welds.
2. Make sure there are no holes or rusting.
3. Make sure the cushion rubber is not worn or cracked.