Contents: Examination ⬇ Removal ⬇ Installation ⬇ Front section — models with two…⬇ Front Expansion Box/Catalytic…⬇ Central section ⬇ Rear section ⬇
Note: Replace all gaskets and/or O-rings during installation.
Examination
1. Periodically check the exhaust system for signs of leaks or damage. Also check the rubber mounts, replace if necessary.
2. Small holes or cracks can be repaired using special means for repairing the exhaust system, but if the damage is serious, replacement is necessary.
Removal
3. The original production exhaust system consists of four separate sections that can be replaced individually.
4. On models with a catalytic converter, an oxygen sensor is mounted on the front section of the exhaust system. The catalytic converter is mounted in a box in front of the conventional exhaust system. Manufacturers do not specify any intervals for replacing the catalytic converter.
5. Before replacing individual parts of the exhaust system, it is recommended to inspect all parts. If there is corrosion or damage on more than one part of the system, it is more cost-effective to replace the entire system.
6. Separate parts of the exhaust system can be removed as follows. Front section - single overhead camshaft (SOHC) models.
7. On models with a catalytic converter, disconnect the negative cable from the battery, disconnect the wiring from the oxygen sensor, which is located behind the coolant expansion tank.
8. Raise the vehicle and support it on axle stands placed under the sides of the body frame.
9. Remove the two mounting bolts and disconnect the front section of the exhaust system from the front box or catalytic converter (depending on the model). Remove the O-ring and springs (see illustration).
10. Unscrew the front section of the exhaust system from the bracket on the cylinder block (see illustration).
11. Loosen and remove the four bolts securing the exhaust outlet pipe to the exhaust manifold, remove the front section of the exhaust system (see illustration). Remove the gasket between the manifold and the outlet pipe.
Installation
12. Install in reverse order, but use a new gasket when connecting the exhaust outlet pipe to the manifold, and a new O-ring when connecting the soft joint. Tighten all fasteners to the specified torque Specifications.
Front section — models with two overhead camshafts (DOHC).
Removal
13. Proceed as described in points 7 and 8.
14. Remove the lower engine skid plate as described in Section 11.
15. Proceed as described in points 9 and 10.
16. Working in the engine compartment, unscrew the bolts securing the exhaust manifold heat shield to the cylinder head
17. Unscrew the two lower exhaust manifold mounting nuts, which also secure the heat shield brackets, and remove the shield (see illustration).
18. Remove the remaining manifold mounting nuts, then remove the manifold/front section of the exhaust system from the vehicle. Remove the manifold gasket.
19. Some manifold struts may unscrew from the cylinder head when the manifold mounting nuts are removed. In this case, the struts must be screwed back into the cylinder head once the manifold is removed.
Installation
20. Perform the installation in reverse order, but use a new manifold gasket and a new O-ring on the soft joint. Tighten all fasteners with the prescribed tightening force Specifications.
Front Expansion Box/Catalytic Converter
Removal
21. Proceed as described in points 8 and 9.
22. Remove the nuts and bolts, disconnect the expansion box/catalytic converter from the connecting flange of the central section of the exhaust system. Remove the gasket.
23. Remove the expansion box/catalytic converter from the vehicle.
Installation
24. Install in reverse order, but use a new O-ring on the soft joint and a new gasket on the coupling flange. Tighten all fasteners to the torque specified in the Specifications.
Central section
Removal
25. Raise the vehicle and support it on axle stands, positioned under the sides of the body frame.
26. Loosen the clamping bolt and separate the central section of the exhaust system from the rear section (see illustration). If necessary, tap around the joint with a hammer to help separate. Note that the end of the center section fits inside the rear section.
27. Proceed as described in paragraph 22.
28. Release the center section from the rubber hangers on the bottom and remove it from under the car (see illustration).
Installation
29. Install in reverse order, but use a new gasket on the connecting flange, and when connecting the central and rear sections, lubricate the pipes with a special paste for assembling the exhaust system. Tighten all fasteners to the tightening torque specified in the Specifications
Rear section
Removal
30. Proceed as described in points 25 and 26.
31. Release the rear section from the rubber cushions on the bottom and remove it from under the car.
Installation
32. Install in reverse order, but when connecting the central and rear sections, lubricate the pipes with a special paste for assembling the exhaust system. Tighten the clamping bolt with the tightening force specified Specifications.
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