Exhaust System: Service and Repair

Part 1:

Part 2:

Removal and Installation

CAUTION:
^ Be sure to use genuine exhaust system parts or equivalents which are specially designed for heat resistance, corrosion resistance, and shape.
^ Perform the operation with the exhaust system fully cooled down because the system will be hot just after engine stops.
^ Be careful not to cut your hand on the insulator edge.

REMOVAL
1. Remove cable from exhaust control valve. Refer to Dual mode muffler, "Removal and Installation".
2. Disconnect each joint and mounting using power tool.

INSTALLATION
Install in the reverse order of removal.

CAUTION:
^ Always replace exhaust gaskets with new ones when reassembling.
^ Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 inch) onto a hard surface such as a concrete floor; use a new one.
^ Before installing a new heated oxygen sensor, clean exhaust system threads using the heated oxygen sensor thread cleaner [commercial service tool: J-43897-18 or J-43897-12], and apply antiseize lubricant (commercial service tool).
^ Do not over torque heated oxygen sensor. Doing so may cause damage to the heated oxygen sensor, resulting in the MIL coming on.
^ If the insulator is badly deformed, repair or replace it. If deposits such as mud pile up on the insulator, remove them.
^ When installing insulator avoid large gaps or interference between insulator and each exhaust pipe.
^ Remove deposits and left over gasket material from the sealing surface of each connection. Connect them securely to avoid gas leakage.
^ Temporarily tighten mounting nuts on the exhaust manifold side and mounting bolts on the vehicle side. Check each part for unusual interference, and then tighten them to the specified torque.
^ When installing each clamp, align the protrusion on insulator with the clamp hole.
^ When installing each mounting rubber, avoid twisting or unusual extension in up/down and right/left directions.





^ Install mounting rubbers on rear main muffler as shown.

INSPECTION AFTER INSTALLATION
Install in the reverse order of removal paying attention to the followings.
^ Check clearance between tail tube and bumper is even.
^ With engine running, check exhaust tube joints for gas leakage and unusual noises.
^ Check to ensure that mounting brackets and mounting insulators are installed properly and free from undue stress. Improper installation could result in excessive noise and vibration.