Exhaust System: Service and Repair

EXHAUST SYSTEM REMOVAL/INSTALLATION [LF]

WARNING:
- A hot engine and exhaust system can cause severe burns. Turn off the engine and wait until they are cool before servicing the exhaust system.

1. Remove the battery cover. Removal and Replacement

2. Disconnect the negative battery cable. Removal and Replacement

3. Remove in the order indicated in the table.

4. Remove the exhaust system insulator.

5. Install in the reverse order of removal.










Exhaust System Insulator Removal/Installation Note

1. Remove the exhaust system insulator in the order shown in the figure.

2. Install in the reverse order of removal.









Insulator (Rear) Removal Note

NOTE:
- The insulator (rear) are installed using rivets.

1. Push out the mandrel using a hammer and punch (2-2.8 mm {0.08-0.11 in} diameter).






2. Remove the flange using a drill (5 mm {0.20 in} drill bit).






Seal Ring Removal Note

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






Exhaust Manifold Insulator (Upper) Removal Note

1. Remove the battery and battery tray. Removal and Replacement

2. Remove the drive belt. Service and Repair

3. Remove the under cover. Front Suspension - Transverse Member Removal/Installation

4. Remove the suspension tower bar (joint) and (right side). Service and Repair

5. Remove the generator. Removal and Replacement

6. Remove the insulator.






Exhaust Manifold Removal Note

1. Disconnect the A/F sensor connector and HO2S connector.

2. Move the water pipe and heater hose slightly out of the way.






3. Disconnect the ventilation hose from the cylinder head. Service and Repair

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.






Middle pipe Installation Note

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






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