Exhaust System: Service and Repair

Part 1 Of 2:

Part 2 Of 2:

EXHAUST PIPE ASSY
Removal & Installation and Disassembly & Reassembly
1. REMOVE SHIFT LEVER KNOB SUB-ASSY (M/T TRANSAXLE)
2. REMOVE CONSOLE BOX ASSY REAR





3. REMOVE FLOOR PANEL BRACE FRONT
a. Remove the 2 bolts and floor panel brace front.
4. REMOVE EXHAUST PIPE ASSY TAIL
a. Remove the bolt and clamp.





b. Disconnect the 2 exhaust pipe supports, and remove the exhaust pipe tail and gasket.
5. REMOVE EXHAUST PIPE ASSY FRONT
a. Disconnect the 2 heated oxygen sensor connectors.
b. Remove the grommet.
c. Remove the 2 bolts and 2 compression springs.
d. Disconnect the 2 exhaust pipe supports, and remove the exhaust pipe front.





e. Remove the gasket from the exhaust manifold.





f. Remove the 2 heated oxygen sensors.





6. INSTALL EXHAUST PIPE ASSY FRONT
a. Install the 2 heated oxygen sensors.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)
b. Using vernier calipers, measure the free length of the compression spring.
Minimum length: 40.5 mm (1.594 inch)
If the minimum length is not as specified, replace the compression spring.





c. Using a plastic-faced hammer and a wooden block, tap in a new gasket until its surface is flush with the exhaust manifold.

NOTICE:
^ Tap in the gasket in the correct direction.
^ Do not reuse the removed gasket.
^ Be sure not to push in the gasket when installing the exhaust pipe.

d. Connect the 2 exhaust pipe supports, and install the exhaust pipe front.
e. Install the 2 compression springs and 2 bolts.
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)
f. Connect the 2 heated oxygen sensor connectors.
g. Install the grommet.





7. INSTALL EXHAUST PIPE ASSY TAIL
a. Install a new gasket to the exhaust pipe front.
b. Connect the 2 exhaust pipe supports, and install the exhaust pipe tail.
c. Install the clamp with the bolt as shown in the illustration.
Torque: 32 Nm (326 kgf-cm, 24 ft. lbs.)
8. CHECK FOR EXHAUST GAS LEAKS
9. INSTALL FLOOR PANEL BRACE FRONT
Torque: 20 Nm (199 kgf-cm, 14 ft. lbs.)
10. INSTALL CONSOLE BOX ASSY REAR
11. INSTALL SHIFT LEVER KNOB SUB-ASSY (M/T TRANSAXLE)