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EXHAUST SYSTEM REMOVAL/INSTALLATION [L8, LF, L3 2WD]

EXHAUST SYSTEM REMOVAL/INSTALLATION [L8, LF, L3 2WD]

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Warning
•  When the engine and exhaust system are hot, they can badly burn. Turn off the engine and wait until they are cool before removing the exhaust system.

1.  Disconnect the negative battery cable.

2.  Remove in the order indicated in the table.

3.  Install in the reverse order of removal.

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1
Main silencer
2
TWC, Presilencer
(See TWC Installation Note.)
(See Presilencer Replacement Note.)
3
Seal ring
(See Seal Ring Removal Note.)
(See Seal Ring Installation Note.)
4
Exhaust manifold insulator (upper)
(See Exhaust Manifold Insulator (Upper) Installation Note.)
5
Bracket
(See Bracket Installation Note.)
6
Exhaust manifold
(See Exhaust Manifold Installation Note.)
7
Exhaust manifold gasket
8
Exhaust manifold insulator (lower)
(See Exhaust Manifold Insulator (Lower) Installation Note.)
9
A/F sensor
(See A/F Sensor, HO2S Removal Note.)
10
HO2S
(See A/F Sensor, HO2S Removal Note.)


Seal Ring Removal Note

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

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A/F Sensor, HO2S Removal Note

1.  Remove the A/F Sensor, HO2S using the SST before removing the exhaust manifold.

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Exhaust Manifold Insulator (Lower) Installation Note

1.  Tighten the exhaust manifold insulator (lower) installation bolts in the order shown.

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2.  Verify that there is 3.0—7.0 mm {0.12—0.27 in} gap between the exhaust manifold and the exhaust manifold insulator (lower).

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Exhaust Manifold Installation Note

1.  Tighten the exhaust manifold installation nuts in the order shown.

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Bracket Installation Note

1.  Temporarily tighten the bracket installation bolt by the side of the exhaust manifold.

2.  Verify that there is 2.0—4.0 mm {0.08—0.15 in} gap between the exhaust manifold and the bracket.

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3.  Tighten the bracket installation bolt by the side of the cylinder block.

Tightening torque
37.3—52.0 N·m {3.9—5.3 kgf·m, 27.6—38.3 ft·lbf}

4.  Tighten the bracket installation bolt by the side of the exhaust manifold.

Tightening torque
40—55 N·m {4.1—5.6 kgf·m, 30—40 ft·lbf}


Exhaust Manifold Insulator (Upper) Installation Note

1.  Tighten the exhaust manifold insulator (upper) installation bolts in the order shown.

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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.

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2.  Install the SST to the seal ring so that the SST is even with the flange.

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3.  Press in the seal ring by tapping the SST using a plastic hammer until the seal ring contacts the flange.

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TWC Installation Note

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

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

3.  Apply 1.0—2.5 g {0.036—0.088 oz} of grease (L3Z5 40 589) along the perimeter of the flared section.


Presilencer Replacement Note

Caution
•  Be careful not to deform the pipe when cutting it. If the pipe is deformed, it may not be possible to install the new presilencer correctly.
•  If the pipe is tightened to the U-bolt, the pipe will deform. Consequently, the pipe may not install correctly when reassembling it. Therefore, if the pipe has already been connected by the U-bolt, replace the TWC as a single unit.

1.  Cut the pipe between the TWC and the presilencer in the position shown in the figure.

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2.  Remove burrs from the cut surface on the TWC side using a file.

3.  Install the new presilencer to the TWC using the following procedure.

(1)  Mark the TWC in the position shown in the figure (new presilencer installation position).
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(2)  Apply silicone sealant to the marked position along the entire perimeter.
(3)  Insert the U-shaped bolt into the new presilencer.
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(4)  Engage the new presilencer with the TWC.
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(5)  Align the cut surface on the new presilencer with the marked position.

4.  Tighten the U-shaped bolt between the new presilencer and the TWC using the following procedure.

(1)  Align the U-shaped bolt into the position shown in the figure.
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(2)  Tighten the U-shaped bolt.

Caution
•  Tighten the U-shaped bolt in three or four steps, left and right equally, to prevent clamp deformation.
Tightening torque
40.3—54.7 N·m {4.11—5.57 kgf·m, 29.8—40.3 ft·lbf}