Exhaust pipe ASSY (FA20)
Components Removal / installation
INTAKE / EXHAUST
EXHAUST PIPE ASSY (FA20)
EXPLODED VIEW
REMOVAL
1. Under cover front AL removal
(1) Remove the 12 bolts, release the seven clips, and then remove the under cover front AL.
2. Under cover COMPL T/M removal
(1) Remove the seven bolts to remove the under cover COMPL T/M.
3. Removal of exhaust pipe ASSY FR
(1) Remove the two nuts and remove the exhaust pipe ASSY FR.
(2) Remove the two nuts, two bolts and two compression springs to remove the exhaust pipe ASSY CTR.
(3) Remove the bolt and remove the exhaust pipe ASSY FR.
(4) Remove the two gaskets.
4. Removal of exhaust pipe ASSY CTR
(1) Remove the two nuts and two bolts to remove the exhaust tail pipe ASSY.
(2) Remove the cushion rubber, and remove the exhaust pipe ASSY CTR.
(3) Remove the gasket.
5. Exhaust tail pipe ASSY removal
(1) Remove the four cushion rubbers and remove the exhaust tail pipe ASSY.
6. Tail pipe baffle removal (with tail pipe baffle)
(1) Remove the two bolts and remove the two tail pipe baffles.
7. Exhaust manifold removal (Refer to 
)
)8. Removal of exhaust pipe SUB-ASSY FR
(1) Front strut tower bar LH removal (Refer to )
)(2) Front strut tower bar RH removal (Refer to )
)(3) Removal of air cleaner case SUB-ASSY (Refer to )
)
(4) Engine wiring disconnection
(a) Release the four clamps and disconnect the engine wiring.
(b) Remove the bolt and three clamps, and then disconnect the engine wiring.
(5) Disconnection of clutch flexible hose bracket No.1 (RHD transmission M/T)
(a) Remove the clip, and disconnect the master cylinder-to-release cylinder hose.
(b) Remove the bolt, and disconnect the clutch flexible hose bracket No. 1.
(6) Remove the 2 nuts on the engine mount.
(7) Tie the joint pipe to the front suspension crossmember SUB-ASSY with rope.
NOTE:
This procedure is necessary to prevent the joint pipe from falling off.
(8) Install the SST to the cylinder block.
Standard value:
Captions in illustration
| *1 |
12281-38150 |
| *2 |
90119-14120 |
SST
12281-38150
90119-14120
Standard value:
Tightening torque=43N·m
{
439kgf·cm}
{31.7ft·lbf}
(9) Release the clamp and disconnect the engine wiring.
Captions in illustration
| *1 |
LH |
| *2 |
RH |
NOTE:
This procedure is required to prevent the engine wiring from damaging.
(10) Install the SST to the vehicle.
SST
99099AJ000
18679AA020
CAUTION:
·When installing the SST to the vehicle, do not damage the engine wiring.
·Use a shackle with a load capacity of 250 kg (551 lb) or more.
·Use a shackle with a load capacity of 250 kg (551 lb) or more.
(11) Lift the engine ASSY a little bit at a time until the stud bolt of the engine mount is removed from the front crossmember.
CAUTION:
·To avoid the damage to the SST, apply grease or lubricant to the threaded portion.
·To avoid the damage to the vehicle and parts, perform lifting operation a little bit at a time while checking the clearance in each part.
·Lift up the engine ASSY until the position where the intake manifold (#4) and A/C suction hose contact lightly.
·Insert a cloth etc. between the intake manifold (#4) and A/C suction hose to protect the parts of them.
·To avoid the damage to the vehicle and parts, perform lifting operation a little bit at a time while checking the clearance in each part.
·Lift up the engine ASSY until the position where the intake manifold (#4) and A/C suction hose contact lightly.
·Insert a cloth etc. between the intake manifold (#4) and A/C suction hose to protect the parts of them.
(12) Install the SST between engine mount and front crossmember.
SST
18632AA020
(13) Remove the rope which secures the exhaust pipe SUB-ASSY FR to the front suspension crossmember SUB-ASSY.
(14) Remove the exhaust pipe SUB-ASSY FR.
INSTALLATION
1. Exhaust pipe SUB-ASSY FR installation
(1) Tie the exhaust pipe SUB-ASSY FR to the front suspension crossmember SUB-ASSY with the rope.
NOTE:
This operation is required to avoid dropping the exhaust pipe SUB-ASSY FR.
2. Removal of SST
(1) Using the SST, lift the engine ASSY.
(2) Remove the SST.
SST
18632AA020
(3) Install the two nuts of engine mounting.
Standard value:
Standard value:
Tightening torque=45N·m
{
459kgf·cm}
{33.2ft·lbf}
(4) Remove the rope which secures the joint pipe to the front suspension crossmember SUB-ASSY.
(5) Remove the SST from the vehicle.
(6) Remove the SST from the cylinder block.
(8) Connection of clutch flexible hose bracket No. 1 (RHD transmission M/T)
(a) Using the bolt, connect the clutch flexible hose bracket No. 1.
Standard value:
Standard value:
Tightening torque=7.5N·m
{
77kgf·cm}
{5.5ft·lbf}
(b) Using the clip, connect the master cylinder-to-release cylinder hose.
(9) Engine wiring connection
(a) Connect the engine wiring with the bolt and three clamps.
Standard value:
Standard value:
Tightening torque=1.1N·m
{
112kgf·cm}
{8.1ft·lbf}
(b) Using 4 clamps, connect the engine wire.
(10) Installation of air cleaner case SUB-ASSY (Refer to )
)(11) Installation of front strut tower bar LH (Refer to )
)(12) Installation of front strut tower bar RH (Refer to )
)3. Exhaust manifold installation (Refer to )
)
4. Tail pipe baffle installation (with tail pipe baffle)
(1) As in the figure, align the tail pipe baffle protrusion and the cutout of the exhaust tailpipe ASSY, and push in until it hits the tailpipe baffle stopper.
Captions in illustration
| *a |
Cutout |
| *b |
Protrusion portion |
| *c |
Stopper |
(2) Install the two tail pipe baffles with the two bolts.
Standard value:
Standard value:
Tightening torque=7.5N·m
{
77kgf·cm}
{5.5ft·lbf}
5. Exhaust tail pipe ASSY installation
(1) Install the exhaust tail pipe ASSY with the four cushion rubbers.
6. Installation of exhaust pipe ASSY CTR
(1) Install the exhaust pipe ASSY CTR with the cushion rubber.
(2) Install the exhaust pipe ASSY CTR to the exhaust tail pipe ASSY via a new gasket with the two bolts and two new nuts.
Standard value:
Standard value:
Tightening torque=48N·m
{
490kgf·cm}
{35.4ft·lbf}
7. Installation of exhaust pipe ASSY FR.
(1) Temporarily tighten the exhaust pipe ASSY FR to the bracket with the bolt.
(2) Install the exhaust pipe ASSY FR to the exhaust pipe ASSY CTR via a new gasket with the two nuts, two bolts and two compression rings.
Standard value:
Standard value:
Tightening torque=18N·m
{
184kgf·cm}
{13.3ft·lbf}
(3) Install the exhaust pipe ASSY FR to the exhaust pipe SUB-ASSY FR via a new gasket with the two nuts.
Standard value:
Standard value:
Tightening torque=42.5N·m
{
433kgf·cm}
{31.3ft·lbf}
(4) Finally tighten the bolt for securing the bracket of exhaust pipe ASSY FR.
Standard value:
Standard value:
Tightening torque=50N·m
{
510kgf·cm}
{36.9ft·lbf}
8. Exhaust gas leakage check
(1) Make sure that there is no exhaust gas leakage from the connections of exhaust pipes and the mounting portion of each sensor.
9. Shift lever position check (transmission A/T) (Refer to )
)10. Under cover COMPL T/M installation
(1) Install the under cover COMPL T/M with the seven bolts.
Standard value:
Standard value:
Tightening torque=7.5N·m
{
77kgf·cm}
{5.5ft·lbf}
