EXHAUST SYSTEM SUBARU SVX 1992 2-9 Page C COMPONENT PARTS Exhaust System W SERVICE PROCEDURE Exhaust System Exhaust Manifold Front Exhaust Pipe Rear Catalytic Converter Rear Exhaust Pipe Muffler ASSY 10 EXHAUST SYSTEM 2-9 icyooh C COMPONENT PARTS Exhaust System o T3 T3 34 v ,~ T3 v- T4 T3~~ ~13 T3 T3 O L_ t i i i I i T3 Oxygen sensor Front exhaust pipe ASSY (LH) Front exhaust pipe ASSY (RH) 12 13 Hanger bracket 14 15 16 17 `` ~ 21 22 23 24 25 26 27 28 16 ;-" lss T4 - 29 30 31 T4 _ i -!~-, W T1 Tightening torque : N-m (kg-m, ft-1b) T1 : 17 2-20 1(1 75-2.05,12 7-14 8) T2 : 34 - 44 (3 - 4.5, 25 - 33) T3 : 29 - 39 (3 - 4, 22 - 29) T4 : 13-23(1.3-2 3,9-17) Nut Gasket Spring Bolt Rear catalytic converter Protector 20 Gasket A i Fig 11 18 19 r / i T1 ~ Gasket T3 15 15 11 '' c-' 10 T4' ^0 ~' ~ 18 \~r / T3 ,- ,"~' ' ' - '- ; ®~ e4 lt, T3 © ' ,~ - - Gasket Inner exhaust manifold cover (RH) Exhaust manifold (RH) Outer exhaust manifold cover (RH) Gasket © ~ ll9C- Outer exhaust manifold cover (LH) Exhaust manifold (LH) Inner exhaust manifold cover (LH) I 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 Rear exhaust pipe hanger Cushion Rear exhaust pipe hanger Muffler Band Seat bearing Rear muffler bracket Tail pipe cutter (LH) Tail pipe cutter (RH) Muffler hanger (LH) Muffler hanger (RH) Cushion rubber Rear exhaust pipe Exhaust cover Muffler cover Lower front pipe cover Lower converter cover Lower rear pipe cover Front insulator Rear insulator Front exhaust pipe Front insulator Upper front pipe cover Upper converter cover Rear insulator Upper pipe cover C2-403 EXHAUST SYSTEM W SERVICE PROCEDURE Exhaust System [W1A0] 2-9 1) Check to make sure clearances between parts and car body are larger than specified values 2) If any clearance is not, loosen all connections 3) Adjust where necessary to obtain proper clearance 4) Tighten all connections to specified torque A: ADJUSTMENT B A0 Front sub frame Performance rod More than 15 ( 59) Steering gear box boots More than 16 (0 63) co More than 25 (0 98) Crossmember More than 25 (0 98) D-D Propeller shaft More than 13 (0 51) F-F E-E Rear catalytic Converter - Propeller shaft DOJ Rear exhaust pipe More than Exhaust 13 (0 51) Exhaust cover Rear differential More than 20(0 79) More than 20 (0 79) More than 13 (0 51) More than 13 (0 51) More than 20 (0 79) More than 20 (0.79) G-G More than 30 (1 18) Rear exhaust pipe Bumper More than 30 (1 18) - More than 17 (0 67) r More than 20 (0 79) Tail pipe cutter C2-125 Fig 2-9 [w2Ao] EXHAUST SYSTEM Exhaust Manifold A: REMOVAL Tightening torque N-m (kg-m, ft-Ib) T1 : 17 2-20.1 (1 75-2 05,12 7-14 8) T2 : 34 - 44 (3 - 5, 25 - 33) T3 : 29 - 39 (3 - 4, 22 - 29) F CD C) T3~ C5 1, A-7 C2-126 Fig 1) Disconnect Oz sensor harness 2) Remove front under cover 3) Remove exhaust manifold covers 4) Remove front exhaust pipes (Ref to Front Exhaust Pipe [W3A0] ) 6) Remove exhaust manifolds B : INSTALLATION Installation is in the reverse order of removal procedures 5) Disconnect EGR pipe from exhaust manifold RH i \ c o~ ~ o /j`^, \ Observe the following : 1) Be sure to install a new gasket EGR pipe 2) Use only nuts specified by the manufacturer ~\D ~I ` ~\ I n Fig C2-127 EXHAUST SYSTEM [W3A0] 2-9 W SERVICE PROCEDURE Front Exhaust Pipe A: REMOVAL Tightening torque : N"rn (kg-m, ft-Ib) T1 : 17 - 20 (1 75 - 2.05, 12 - 14 8) T2 : 29-39 (3-4,22-29) T3 : 13-23(1 3-2 3,9-17) _ (~\\6 T2 \ c2-128 Fig To prevent exhaust pipes from dropping, not remove the left and right exhaust pipes at the same time ; always remove one at a time 1) Disconnect oxygen sensor harness 2) Remove front under cover 3) Remove exhaust manifold covers 4) Remove rear catalytic converter protector 5) Remove nuts which connect front exhaust pipe to exhaust manifold 6) Loosen nuts which hold front exhaust pipe to hanger bracket c2-129I Fig 7) Disconnect front exhaust pipe from rear catalytic converter 8) Remove nuts which hold front exhaust pipe to hanger bracket and remove front exhaust pipe 9) Similarly, remove the other front exhaust pipe 10) If necessary, remove heat sealed covers 2-9 Iw3B0] EXHAUST SYSTEM B : INSTALLATION Installation is in the reverse order of removal procedures Observe the following: 1) Be sure to install a new gasket 2) Use only nuts specified by the manufacturer Be sure to install bolts, springs and nuts in the order indicated in the figure Rear Exhaust Pipe I B: INSTALLATION 1) Insert rear exhaust pipe bracket into rubber cushion To facilitate insertion, apply a coat of SUBARU CRC5-56 (004301003) to the mating area of rubber cushion in advance 2) Loosen the seal bearing band and install it over the rear exhaust pipe in advance 3) Place the seal bearing between the rear exhaust pipe and muffler ASSY, and tighten the seal bearing band Do not allow clearances to exist between the seal bearing and rear exhaust pipe, or muffler ASSY while tightening the band Seal bearing band Rear exhaust pipe Seal bearing Fig 4 Rear Catalytic Converter Muffler B: INSTALLATION Installation is in the reverse order of removal procedures Observe the following: 1) Be sure to install a new gasket 2) Use only nuts specified by the manufacturer Be sure to install bolts, springs and nuts in the order indicated in the figure Fig C2-134 Fig 4) Connect rear exhaust pipe to rear catalytic converter Be sure to install bolts, springs and nuts in the order < Ref to Rear Catalytic Converter [W4B0] > 5) Install rear catalytic converter protector EXHAUST SYSTEM [w4BO1 2-9 Rear Catalytic Converter ~ A: REMOVAL 7T, I 61 va~ T1 Tightening torque : N.m (kg-m, ft-Ib) T1 :13-23(1 3-2 3,9-17) U C2-131 Fig 1) Remove rear catalytic converter protector 2) Disconnect rear catalytic converter from front exhaust pipes 3) Disconnect rear catalytic converter from rear exhaust pipe 4) Remove rear catalytic converter B : INSTALLATION Installation is in the reverse order of removal procedures Observe the following : 1) Be sure to install a new gasket 2) Use only nuts specified by the manufacturer Be sure to install bolts, springs and self-locking nuts in the order indicated in the figure Always install new self-locking nuts Fig EXHAUST SYSTEM 2-9 [W5A0] Rear Exhaust Pipe ~ A: REMOVAL O T2 r- `'` _-® r- Alb-,-F Tightening torque : N-rn (kg-m, ft-Ib) T1 :13-23(1 3-2 3,9-17) T2 : 29 - 39 (3 - 4, 22 - 29) T2 T1 C2-404 Fig 10 1) Remove rear catalytic converter protecter 2) Disconnect rear exhaust pipe from rear catalytic converter 3) Loosen seal bearing band and disconnect rear exhaust pipe from muffer ASSY When disconnecting rear exhaust pipe from muffer ASSY, be careful not to drop seal bearing 4) Remove rear exhaust pipe from rubber cushion To facilitate its removal, apply a coat of SUBARU CRC5-56 (004301003) in advance B: INSTALLATION 1) Insert rear exhaust pipe bracket into rubber cushion To facilitate insertion, apply a coat of SUBARU CRC5-56 (004301003) to the mating area of rubber cushion in advance 2) Loosen the seal bearing band and install it over the rear exhaust pipe in advance 3) Place the seal bearing between the rear exhaust pipe and muffler ASSY, and tighten the seal bearing band Do not allow clearances to exist between the seal bearing and rear exhaust pipe, or muffler ASSY while tightening the band Seal bearing bb and C2-406 Fig 11 EXHAUST SYSTEM 4) Connect rear exhaust pipe to rear catalytic converter Be sure to install bolts, springs and self-locking nuts in the order (Ref to Rear Catalytic Converter [W4B0] ) Always install new self-locking nuts 5) Install rear catalytic converter protector Seal bearing band Rear exhaust pipe Seal bearing Muffler Fig 12 [w5BO] 2-9 C2-134 2-9 [W6AOJ EXHAUST SYSTEM Muffler ASSY IL A: REMOVAL Tightening torque : N-m (kg-m, ft-Ib) T1 : 29 - 39 (3 - 4, 22 - 29) i i Tt s ~ ~ i T1 "~Y® i T1 C2-405 Fig 13 Always work with a helper when removing or installing the muffler ASSY 1) To prevent damage to bumper near muffler, wrap a cloth around tail pipe cutters 2) Loosen seal bearing band and disconnect muffler ASSY from rear exhaust pipe When disconnecting muffer ASSY from rear exhaust pipe, be careful not to drop seal bearing 3) Remove muffler ASSY from rubber cushions To facilitate their removal, apply a coat of SUBARU CRC5-56 (004301003) to them in advance 4) Remove tail pipe cutters from muffler ASSY FB INSTALLATION 1) Instsll tail pipe cutters 2) Insert muffler ASSY brackets into rubber cushions To facilitate insertion, apply a coat of SUBARU CRC5-56 (004301003) to the mating area of rubber cushions in advance 3) Loosen the seal bearing band and install it over the rear exhaust pipe in advance 4) Place the seal bearing between the rear exhaust pipe and muffler ASSY, and tighten the seal bearing band Do not allow clearances to exist between the seal bearing and rear exhaust pipe, or muffler ASSY while tightening the band Seal bearing bb and C2-406 Fig 14 10 EXHAUST SYSTEM Seal bearing band Rear exhaust pipe Seal bearing Muffler Fig 15 C2-134 11 [w6Boj 2-9 ... - Gasket Inner exhaust manifold cover (RH) Exhaust manifold (RH) Outer exhaust manifold cover (RH) Gasket © ~ ll9C- Outer exhaust manifold cover (LH) Exhaust manifold (LH) Inner exhaust manifold.. .EXHAUST SYSTEM 2-9 icyooh C COMPONENT PARTS Exhaust System o T3 T3 34 v ,~ T3 v- T4 T3~~ ~13 T3 T3 O L_ t i i i I i T3 Oxygen sensor Front exhaust pipe ASSY (LH) Front exhaust pipe... 25 (0 98) D-D Propeller shaft More than 13 (0 51) F-F E-E Rear catalytic Converter - Propeller shaft DOJ Rear exhaust pipe More than Exhaust 13 (0 51) Exhaust cover Rear differential More than