Subaru Car 1998-05

Exhaust Manifold

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Due to the unique design of the Subaru engine, an exhaust manifold is not used. The exhaust enters directly into the front Y-pipe.

General Information



Due to the unique design of the Subaru engine, an exhaust manifold is not used. The exhaust enters directly into the front Y-pipe.

Removal & Installation



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Front Oxygen (O 2 S) sensor electrical connector
     
    Front under cover, if equipped
     
    Rear O 2 S electrical connector, on California vehicles
     
    Rear O 2 S sensor electrical connector on all vehicles, except California
     
    Y-pipe-to-rear pipe mounting nuts and separate the Y-pipe from the rear pipe
     
    Bolts that secure the front Y-pipe to the cylinder head
     
    Y-pipe from the hanger bracket
     
    Front exhaust pipe from the catalytic converter and discard the gaskets
     

  4.  

To install:

  1. Clean all gasket surfaces completely.
  2.  
  3. Install or connect the following:

    New gaskets
     
    Front catalytic converter to front exhaust pipe. Tighten the bolts to 18.8-26 ft. lbs. (25-35 Nm).
     
    Y-pipe. Temporarily tighten the bolt which holds the center exhaust pipe to the hanger bracket.
     
    Y-pipe, to the cylinder head. Tighten the retainers to 18.8-26 ft. lbs. (25-35 Nm).
     
    Y-pipe to the rear pipe. Tighten the retainers to 9.4-16.6 ft. lbs. (13-23 Nm).
     

  4.  
  5. Tighten the center exhaust pipe to hanger bracket bolt to 22.4-29.6 ft. lbs. (30-40 Nm).

    Rear O 2 S sensor electrical connector, on all except California models
     
    Rear O 2 S sensor electrical connector, on California models
     
    Front O 2 S sensor electrical connector
     
    Front under cover, if equipped
     
    Negative battery cable
     

  6.  
  7. Start the engine and check for exhaust leaks.
  8.  

1.8L & 2.5L Engines

CAUTION
The exhaust pipe may be hot; DO NOT perform any work until the system has completely cooled.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Disconnect the O 2 sensor electrical wiring.
  6.  
  7. Remove the front under cover.
  8.  
  9. Remove the bolts securing the exhaust manifold covers and remove the covers.
  10.  
  11. Remove the front pipe-to-center pipe mounting nuts.
  12.  
  13. Remove the nuts that secure the exhaust pipe to the cylinder head and remove the exhaust pipe.
  14.  
  15. Discard the gaskets.
  16.  
  17. Installation is the reverse of removal. Secure all components to specifications.
  18.  
  19. Clean all gasket surfaces completely.
  20.  
  21. Install the exhaust pipe to the cylinder head using new gaskets. Tighten the mounting nuts as follows:
    1. Turbocharged engines-28-33 ft. lbs. (34-44 Nm).
    2.  
    3. Non-turbocharged engines-22-30 ft. lbs. (30-40 Nm).
    4.  

  22.  
  23. Using new gaskets, connect the exhaust pipe to the center pipe. Tighten the mounting nuts as follows:
    1. Turbocharged engines-19-26 ft. lbs. (25-35 Nm).
    2.  
    3. Non-turbocharged engines-9-17 ft. lbs. (13-23 Nm).
    4.  

  24.  
  25. Start the engine and check for exhaust leaks.
  26.  

2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Front Oxygen Sensor (O2S)
     
    Front undercover, if equipped
     
    Lower exhaust manifold cover on the right hand side
     
    Upper and lower exhaust manifold covers on the left hand side
     
    Nuts and bolts that attach the front exhaust pipe to the turbocharger joint pipe
     
    Nuts that attach the front exhaust pipe to the to the cylinder head while holding the front pipe
     
    Front exhaust pipe assembly
     
    Covers from the front exhaust pipe and manifold
     
    Front exhaust pipe from the manifolds and discard the gaskets
     

  4.  


    Click image to see an enlarged view

    Fig. Location of the front exhaust pipe retainers-2.0L engines


To install:

  1. Clean all gasket surfaces completely.
  2.  
  3. Install or connect the following:

    New gaskets
     
    Front exhaust pipe to the manifolds and tighten the retainers to 26 ft. lbs. (35 Nm)
     
    Covers to the front exhaust pipe and tighten to 18 ft. lbs. (25 Nm)
     
    Upper exhaust manifold cover on the right hand side and tighten the retainers to 13 ft. lbs. (19 Nm)
     
    Front exhaust pipe assembly and tighten the retainers to 26 ft. lbs. (35 Nm)
     
    Right hand side manifold to the turbocharger joint pipe and tighten the retainers to 13 ft. lbs. (19 Nm)
     
    Upper and lower manifold covers on the left hand side to 13 ft. lbs. (19 Nm)
     
    Front O2S
     
    Front undercover, if equipped
     
    Negative battery cable
     

  4.  

  1. Remove or disconnect the following:

    Negative battery cable
     
    Front Oxygen Sensor (O 2 S)
     
    Front undercover, if equipped
     
    Lower exhaust manifold cover on the right hand side
     
    Upper and lower exhaust manifold covers on the left hand side
     
    Nuts and bolts that attach the front exhaust pipe to the turbocharger joint pipe
     
    Nuts that attach the front exhaust pipe to the to the cylinder head while holding the front pipe
     
    Front exhaust pipe assembly
     
    Covers from the front exhaust pipe and manifold
     
    Front exhaust pipe from the manifolds and discard the gaskets

    Click image to see an enlarged view

    Fig. Location of the front exhaust pipe retainers-2.0L engine

     

  2.  

To install:

  1. Clean all gasket surfaces completely.
  2.  
  3. Install or connect the following:

    New gaskets
     
    Front exhaust pipe to the manifolds and tighten the retainers to 26 ft. lbs. (35 Nm)
     
    Covers to the front exhaust pipe and tighten to 18 ft. lbs. (25 Nm)
     
    Upper exhaust manifold cover on the right hand side and tighten the retainers to 13 ft. lbs. (19 Nm)
     
    Front exhaust pipe assembly and tighten the retainers to 26 ft. lbs. (35 Nm)
     
    Right hand side manifold to the turbocharger joint pipe and tighten the retainers to 13 ft. lbs. (19 Nm)
     
    Upper and lower manifold covers on the left hand side to 13 ft. lbs. (19 Nm)
     
    Front O 2 S
     
    Front undercover, if equipped
     
    Negative battery cable
     

  4.  

3.3L Engines


Click image to see an enlarged view

Fig. Loosen the EGR pipe attached to the exhaust manifold-3.3L engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Disconnect the O 2 sensor electrical harness.
  6.  
  7. Remove the front undercover, if equipped.
  8.  
  9. Remove the bolts securing the exhaust manifold covers and remove.
  10.  
  11. Remove the front pipe-to-exhaust manifold mounting nuts.
  12.  
  13. Disconnect the EGR pipe from the exhaust manifold, only if the right side manifold is being removed.
  14.  
  15. Remove the exhaust manifold mounting nuts, then remove the exhaust manifold.
  16.  
  17. Clean all gasket material from both mating surfaces.
  18.  

To install:

  1. Install the exhaust manifold using new gaskets. Install the mounting nuts and tighten the nuts to 25-33 ft. lbs. (32-43 Nm).
  2.  
  3. Connect the EGR pipe to the right manifold, if disconnected.
  4.  
  5. Connect the exhaust pipe to the exhaust manifold and tighten the mounting nuts to 22-29 ft. lbs. (29-38 Nm).
  6.  
  7. Install the exhaust manifold covers and cover mounting bolts. Tighten the bolts to 13-15 ft. lbs. (17-19 Nm).
  8.  
  9. Before servicing the vehicle, refer to the Precautions section.
  10.  

Except 2.0L Engine & 1997 1.8L, 2.5L & 3.3L Engines
  1. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner case, if necessary
     
    Front Oxygen Sensor (O 2 S)
     
    Front undercover
     
    Rear O 2 S electrical connector
     
    Y-pipe-to-rear pipe mounting nuts and separate the Y-pipe from the rear pipe
     
    Bolts that secure the front Y-pipe to the cylinder head
     
    Y-pipe from the hanger bracket
     
    Front exhaust pipe from the catalytic converter and discard the gaskets
     

  2.  

To install:

  1. Clean all gasket surfaces completely.
  2.  
  3. Install or connect the following:

    New gaskets
     
    Front catalytic converter to front exhaust pipe.
     
    Y-pipe. Temporarily tighten the bolt that holds the center exhaust pipe to the hanger bracket.
     
    Y-pipe, to the cylinder head.
     
    Y-pipe to the rear pipe. Tighten the retainers.
     

  4.  
  5. Tighten the center exhaust pipe to hanger bracket

    Rear O 2 S electrical connector
     
    Front O 2 S electrical connector
     
    Front undercover, if equipped
     
    Air cleaner case, if removed
     
    Negative battery cable
     

  6.  
  7. Start the engine and check for exhaust leaks.
  8.  

 
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