Honda Accord/Prelude 1984-1995 Repair Guide

Safety Precautions

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For a number of reasons, exhaust system work can be the most dangerous type of work you can do on your car. Always observe the following precautions:



Support the car extra securely. Not only will you often be working directly under it, but you'll frequently be using a lot of force to dislodge rusted parts. This can cause a car that's improperly supported to shift and possibly fall.
 
Wear goggles. Exhaust system parts are always rusty. Metal chips can be dislodged, even when you're only turning rusted bolts. Attempting to pry pipes apart with a metal tool makes the chips fly even more frequently.
 
If you're using any source of heat, keep it a great distance from either the fuel tank or lines. Stop what you're doing and feel the temperature of the fuel lines on the tank frequently. Even slight heat can expand and/or vaporize fuel, resulting in accumulated vapor, or even a liquid leak.
 
Watch where your hammer blows fall and make sure you hit squarely. You could easily tap a brake or fuel line when you hit an exhaust system part with a glancing blow. Inspect all lines and hoses in the area where you've been working.
 


CAUTION
Be very careful when working on or near the catalytic converter. External temperatures can reach well over 500°F (260°C), causing severe burns. Removal or installation should be performed only on a cold exhaust system.



It is quite helpful to use solvents designed to loosen rusted bolts or flanges. Soaking rusted parts the night before you do the job can speed the work of freeing rusted parts considerably. Remember that these solvents are often flammable. Apply only to parts after they are cool!
 

The exhaust system of Accord and Prelude vehicles consists of several pieces. Thankfully, the pieces are attached by nuts and bolts rather than being welded. Each bolted joint contains a gasket which must be replaced whenever repairs are made.

The first section of pipe connects the exhaust manifold to the catalytic converter. The catalytic converter is a sealed, non-serviceable unit which can be easily unbolted from the system and replaced if necessary.

The exhaust system is attached to the body by several welded hooks and flexible rubber hangers; these hangers absorb exhaust vibrations and isolate the system from the body of the car. The hangers MUST be in place and correctly mounted to avoid vibration and body-contact. A series of metal heat shields runs along the exhaust piping, protecting the underbody from excess heat. The heat shields must always be reinstalled when a pipe or component is replaced.

The heat shields can be a source of several irritating sounds including buzzes or rattles related to engine speed. Make certain the shields are tightly attached and free of gravel.

The system terminates in the muffler and tailpipe at the rear of the car. The entry pipe, muffler and tailpipe are one-piece and should be replaced as a unit.

When inspecting or replacing exhaust system parts, make sure there is adequate clearance from all points on the body to avoid possible overheating of the floorpan. Check the complete system for broken damaged, missing or poorly positioned parts. Rattles and vibrations in the exhaust system are usually caused by misalignment of parts. When aligning the system, leave all the nuts and bolts loose until everything is in its proper place, then tighten the hardware working from the front to the rear. Remember that what appears to be proper clearance during repair may change as the car moves down the road. The motion of the engine, body and suspension must be considered when replacing parts.

REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11 and 12


CAUTION
DO NOT perform exhaust repairs with the engine or exhaust hot. Allow the system to cool completely before attempting any work. Exhaust systems are noted for sharp edges, flaking metal and rusted bolts. Gloves and eye protection are required. A supply of penetrating oil and rags is highly recommended.

ALWAYS use a new gasket at each pipe joint whenever the joint is disassembled. Use new nuts and bolts to hold the joint properly. These two low-cost items will serve to prevent future leaks as the system ages.

Front Pipe
  1. Raise and safely support the car.
  2.  
  3. Remove the heat shield(s), if present.
  4.  
  5. Remove the nuts securing the pipe to the exhaust manifold.
  6.  
  7. Remove the nuts/bolts securing the front pipe to the converter or mid-pipe (if equipped).
  8.  
  9. If applicable, remove the nuts/bolts securing the pipe to the support bracket.
  10.  
  11. Remove the front pipe and gaskets.
  12.  
  13. Using new gaskets and nuts/bolts, install the front pipe. Tighten the bolts to the specification shown in the appropriate illustration.
  14.  



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Fig. Fig. 1: 1984-85 Accord exhaust system



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Fig. Fig. 2: 1986-89 Accord exhaust system

Mid-Pipe
  1. Raise and safely support the car.
  2.  
  3. Remove the heat shield(s), if present.
  4.  
  5. If applicable, unplug the oxygen sensor connector.
  6.  
  7. Remove the bolts securing the mid-pipe to the converter and front pipe.
  8.  
  9. Using new gaskets and nuts/bolts, install the mid-pipe. Tighten the bolts to the specification shown in the appropriate illustration.
  10.  
  11. If applicable, engage the oxygen sensor connector.
  12.  



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Fig. Fig. 3: 1984-87 Prelude exhaust system



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Fig. Fig. 4: 1988-91 Prelude exhaust system

Catalytic Converter
  1. Raise and safely support the car.
  2.  
  3. Remove the heat shield(s).
  4.  
  5. Remove the three bolts at the front and rear of the converter.
  6.  

Always support the pipe running to the manifold, either by the normal clamps/hangers or by using string, stiff wire, etc. If left loose, the pipe can develop enough leverage to crack the manifold.

  1. Remove the converter and gaskets.
  2.  
  3. Using new gaskets, connect the converter to the exhaust pipes. Tighten the bolts to the specification shown in the appropriate illustration.
  4.  



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Fig. Fig. 5: 1990-93 Accord exhaust system



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Fig. Fig. 6: 1992-95 Prelude exhaust system

Muffler/Tail Pipe

The muffler and tail pipe on all Hondas is one piece and should be replaced as a unit. The chromed tailpipe extension is a separate part and does not come with replacement units; if yours is still in good shape, remove it by loosening the set screw on the bottom of the extension. To remove the muffler and tailpipe:

  1. Elevate and firmly support the rear of the vehicle.
  2.  
  3. Disconnect the nuts holding the muffler and/or tailpipe to the adjacent pipes.
  4.  
  5. Remove or disconnect the clamps and supports holding the pipe at either end. Leave the supports closest to the center in place until last.
  6.  
  7. Remove the last supports or hangers and lower the unit to the ground. At no time should the muffler be allowed to hang partially supported; the leverage can break the next component in line.
  8.  

If the muffler or tailpipe is being replaced due to rust or corrosion, adjacent pipes should be checked for the same condition.

  1. Lift the new unit into place and loosely attach the hangers or supports to hold it in place. Allow some play to adjust the muffler.
  2.  
  3. Using new gaskets, connect each end to the adjoining pipe. Tighten the joint bolts and nuts to the specification shown in the appropriate illustration.
  4.  
  5. Tighten the supports and hangers. Make certain the rubber hangers are securely attached to their mounts.
  6.  



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Fig. Fig. 7: 1994-95 Accord sedan and coupe VTEC exhaust system



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Fig. Fig. 8: 1994-95 Accord wagon VTEC exhaust system



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Fig. Fig. 9: 1994-95 Accord sedan and wagon (except LX without ABS) exhaust system



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Fig. Fig. 10: 1994-95 Accord LX without ABS exhaust system



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Fig. Fig. 11: 1994-95 Accord wagon exhaust system



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Fig. Fig. 12: Accord V-6 exhaust system

 
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