Subaru Coupes/Sedans/Wagons 1985-1996 Repair Guide

Front Exhaust Pipe

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REMOVAL & INSTALLATION



Turbocharged Models
  1. Disconnect the oxygen sensor harness.
  2.  
  3. As required, remove the air duct from the upper shell cover.
  4.  
  5. Loosen (do not remove) the nuts which hold the front exhaust pipe to the exhaust port of the engine.
  6.  
  7. Disconnect the front and rear exhaust pipes.
  8.  
  9. Disconnect the front exhaust pipe and bracket.
  10.  
  11. While holding the front exhaust pipe with one hand, remove the nuts which hold the front exhaust pipe to the exhaust port. The front exhaust pipe can then be disconnected.
  12.  

During installation, do not tighten any connections more then hand tight until the entire exhaust system has been installed. Be sure to install a new gasket at the exhaust port. Use only nuts specified by the manufacturer. Do not remove the gasket placed between the front and rear exhaust pipes. When the front exhaust pipe needs to be replaced, the gasket must be replaced also.

To install:
  1. Install the front exhaust pipe and bracket.
  2.  
  3. Connect the front and rear exhaust pipes.
  4.  
  5. Align exhaust system and tighten all exhaust system nuts and bolts to specification. Work from front to rear.
  6.  
  7. Connect the oxygen sensor harness.
  8.  
  9. Start the engine and allow it to reach operating temperature. Check for leaks.
  10.  

Non-Turbocharged Models
  1. Remove the turbocharger covers, and disconnect the center exhaust pipe. Remove the turbocharger unit.
  2.  
  3. Remove the nuts which hold the turbocharger bracket to the front exhaust pipe.
  4.  
  5. Remove the underguard and right undercover.
  6.  
  7. Loosen the engine mount bracket and pitching stopper. Then slightly raise the engine until the bolts protrude beyond the surface of the crossmember.
  8.  
  9. Disconnect the front exhaust pipe from the engines exhaust port, and remove through the clearance between the crossmember and the cylinder head.
  10.  


WARNING
Be sure to remove the bolts only after the engine has cooled off. Before disassembling parts, spray with penetrating lubricant to loosen rust deposits.

To install:
  1. Install the gasket onto the stud bolts at the engine's exhaust port with its flat surface facing the engine. If the gasket is tilted, it may catch on a thread and then will not drop down over the bolt.
  2.  
  3. Temporarily tighten the front exhaust pipe to engine's exhaust port with the nuts.
  4.  
  5. Lower the engine. Tighten the engine mount bracket and properly adjust the pitching stopper.
  6.  
  7. Install the underguard and right undercover.
  8.  
  9. Connect the front exhaust pipe to the turbocharger bracket.
  10.  
  11. Properly tighten the front exhaust pipe at the engine's exhaust port.
  12.  
  13. Connect the oxygen sensor connector.
  14.  
  15. Install the turbocharger unit, center the exhaust pipe and turbocharger covers.
  16.  

 
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