Pic. 2.612. Exhaust pipe assembly (1ZZ-FE/ 3ZZ-FE)
Pic. 2.613. Exhaust pipe assembly (1CD-FTV)
Disconnect the negative terminal from the battery terminal.
Remove the front footrest.
Remove the heated oxygen sensor.
Removing the rear of the exhaust pipe assembly
Turn out 2 bolts and remove 2 springs.
Remove the rear of the exhaust pipe from the 2 hangers #4 and hanger #5.
Pic. 2.614. Exhaust pipe front gasket
Remove the gasket from the front of the exhaust pipe (pic. 2.614).
Removing the front of the exhaust pipe assembly
Turn out 2 bolts and remove 2 springs.
Pic. 2.615. Exhaust pipe front gasket
Remove the front of the exhaust pipe from 2 hangers #5 (pic. 2.615).
Pic. 2.616. exhaust manifold gasket
Remove gasket from exhaust manifold (pic. 2.616).
Removing the exhaust pipe hanger No. 4
Pic. 2.617. Exhaust Hangers #4
Remove from the body 2 hangers of the exhaust pipe No. 4 (pic. 2.617).
Removing the exhaust pipe hanger No. 5
Pic. 2.618. Exhaust Hangers #5
Remove from the body 3 hangers of the exhaust pipe No. 5 (pic. 2.618).
Installing the exhaust pipe suspension No. 5
Install 3 No. 5 exhaust hangers on the body.
Installing the exhaust pipe hanger No. 4
Install 2 #4 exhaust hangers on the body.
Installation of the front part of the exhaust pipe assembly
Check the free length of the spring.
Pic. 2.619. Measuring the length of a spring
Use a caliper to measure the free length of the spring (pic. 2.619).
Minimum allowable length: 41.5 mm.
If the free length of the spring is less than the minimum allowable value, the spring must be replaced.
Pic. 2.620. Exhaust manifold gasket fitting diagram
Using a wood block and a plastic mallet, press in the new gasket until it is flush with the plane of the exhaust manifold (pic. 2.620).
Note. Make sure the gasket is in the correct position.
Note. The removed seal must not be used.
Note. It is not allowed to press the gasket into the exhaust manifold by installing the front part of the exhaust pipe on the exhaust manifold.
Install the front of the exhaust pipe to hangers #5.
Tighten the 2 spring bolts.
Tightening torque: 43 Nm.
Installation of the rear part of the exhaust pipe assembly
Check the free length of the spring.
Use a caliper to measure the free length of the spring.
Minimum allowable length: 38.5 mm.
If the free length of the spring is less than the minimum allowable value, the spring must be replaced.
Pic. 2.621. Scheme of pressing the gasket of the front part of the exhaust pipe
Using a wooden block and a plastic hammer, press the new gasket into the front of the exhaust pipe (pic. 2.621).
Note. Make sure the gasket is in the correct position.
Note. The removed seal must not be used.
Note. It is not allowed to press the gasket into the exhaust manifold by installing the front part of the exhaust pipe on the exhaust manifold.
Mount the rear of the exhaust pipe to 2 hangers #4 and hanger #5.
Tighten the 2 spring bolts.
Tightening torque: 43 Nm.
Install a heated oxygen sensor.
Connect the negative terminal to the battery terminal.
Tightening torque: 5.4 Nm.
Make sure there are no exhaust gas leaks from the exhaust system.
Install the footrest.