follow ft86club on our blog, twitter or facebook.
FT86CLUB
Ft86Club
Speed By Design
Register Garage Members List Calendar Search Today's Posts Mark Forums Read

Go Back   Toyota GR86, 86, FR-S and Subaru BRZ Forum - FT86CLUB > Technical Topics > DIY (Do-It-Yourself) Guides

DIY (Do-It-Yourself) Guides For all DIYs.


User Tag List

Reply
 
Thread Tools Search this Thread
Old 06-07-2012, 05:41 PM   #1
GrimmSpeed
 
GrimmSpeed's Avatar
 
Join Date: Nov 2011
Drives: '13 BRZ, '12 WRX
Location: Minneapolis, MN
Posts: 1,676
Thanks: 271
Thanked 3,539 Times in 884 Posts
Mentioned: 217 Post(s)
Tagged: 4 Thread(s)
Send a message via AIM to GrimmSpeed Send a message via MSN to GrimmSpeed
Exhaust System/Exhaust Manifold Removal and Replacement

GrimmSpeed DIY Guide Series
Exhaust System/Exhaust Manifold Removal and Replacement
Updated 6/7/12


Click here to download this DIY in a printable .PDF format

Introduction: This guide will illustrate the basics of the BRZ/FR-S exhaust system as well as demonstrate removal and replacement of all exhaust components.

Tools: The tools listed below are suggested for this task. Optional tools are noted.
- Jack, jack stands or lift
- 3/8in drive ratchet
- 3/8in extension
- 14mm, 12mm, 10mm sockets
- 10mm deep well socket (optional)
- Phillips screwdriver
- 14mm wrench
- O2 sensor wrench



Tips: In low-torque applications, we like to use long tools (extensions, deep well sockets, etc) to keep from busting our knuckles worse than we already do.

Procedure:
1. Begin by collecting your tools, safely jacking up your car and popping your hood. Consult your owner’s manual for preferred methods.

2. The first step will be to gain access to the entire exhaust system. This requires the removal of both panels below the car. We’ll remove the aluminum skid plate first. Use a flathead screwdriver, 10mm and 12mm socket along with your ratchet and extensions to remove six (6) plastic clips, four (4) 10mm bolts and eight (8) 12mm bolts. Use your screwdriver to pop the center part of each clip up about 1/4in before pulling the entire clip out. When you’re on your last bolt or two, be ready for the plate to fall. It’s not too heavy, but it can be sharp.



3. Next, remove the seven (7) 10mm bolts holding the second underbody panel to the chassis. Set both aside.



4. Now that the entire exhaust system is exposed, take a minute to identify each piece. Starting at the motor, the components of the system are exhaust manifold > crosspipe > forward midpipe > aft midpipe > axle back/muffler. The catalytic convertors are located in the exhaust manifold and forward midpipe. The forward midpipe also houses a resonator, not to be confused with the catalytic convertor.

5. These steps can be done in a number of difference sequences. We picked the one that seems to be the easiest. The first connection that we’ll loosen is between the crosspipe and the forward midpipe. Use a 14mm wrench to loosen and remove the two (2) bolts. Conveniently, there are weld nuts on the back side, so just be sure to put the bolts someplace where they won’t be lost.





6. Next, remove the 14mm bolt holding the forward midpipe to its hanger.



7. Using your 14mm socket and wrench, remove the two (2) 14mm spring bolts connecting the forward midpipe to the aft midpipe. Once these are loosened, they’ll no longer be in tension, so no need to worry about them flying away.




8. Next, we’ll remove the muffler from the car. The muffler is held on by two (2) 14mm bolts and four (4) rubber hangers, one on each corner of the muffler. Start by removing the bolts and then remove the muffler from its hangers, one at a time. I find that twisting the rubber hanger off of the muffler is the best way to get it started. Be ready when you’ve got it loose, as the muffler is a bit heavy.




9. Now that you’ve got the muffler and the forward midpipe off the car and set aside, removing the aft midpipe is as easy as pulling it off of its hanger and setting it aside as well.



10. The exhaust manifold and crosspipe are the two remaining components in the exhaust system. We’ll tackle the crosspipe first. This smaller pipe runs over the subframe and is a bit tricky to remove. First, remove the two (2) 14mm nuts connecting the crosspipe to the exhaust manifold.



11. Now that the crosspipe is loose, we’ve found it easiest to remove the heatshields from the pipe in order to snake it out without damage to the finish on the firewall and subframe. The heatshields are held on by four (4) 10mm bolts and a clamp with a single 10mm nut. Remove the fasteners along with the four heat shields.



12. With the crosspipe shields removed, the crosspipe has room to be snaked out. It’ll take some trial and error, but trust me, it’ll come out. You’re going to want to pull back and up on the pipe while turning it slightly counterclockwise. We’ll be putting together a video as well that will help. Once that’s out, go ahead and set it aside.

13. The next (and last) step is to remove the exhaust manifold. This is actually pretty straight forward. First, disconnect the two O2 sensor wire connectors in the engine bay. You’ll also need to use a screwdriver to pry the tree clips free so that the sensors can be completely removed. Some people will leave these in and spin the sensors out with the wire still attached. We prefer not to stress the connections like that. For re-assembly, not that the longer sensor harness goes to the rear-most sensor and the connections are color coded





14. Next, use your O2 sensor wrench or socket to remove both sensors from the exhaust manifold. If you’ve disconnected the harnesses from the car, this step is optional, as you’re able to remove the exhaust manifold with the sensors still installed.





15. You’ll need to use your ratchet, extension and 14mm socket to remove the six (6) nuts. Be careful when you’re close to the end, as this piece has some weight to it. Once this is removed, you’re all done (or halfway done, at least).



Closure: Reassembly or installation of aftermarket components will be just about the same as disassembly. As always, questions, comments and suggestions are welcome!

- Matt

Last edited by GrimmSpeed; 02-10-2014 at 12:30 PM.
GrimmSpeed is offline   Reply With Quote
The Following 52 Users Say Thank You to GrimmSpeed For This Useful Post:
3essess (06-14-2014), 70NYD (06-08-2012), airrick (04-08-2020), b rawr z (05-05-2015), BabaYaga (09-17-2016), baldolera (06-16-2012), Billy2224 (06-16-2012), CarzCarzCarz (12-01-2015), charged86 (04-23-2013), Chenslee (06-08-2012), chrisp1992 (02-03-2014), chriswian (08-06-2015), Churnobyl (04-10-2014), civicdrivr (07-05-2012), Coaster (09-17-2012), DAEMANO (06-28-2015), DarkSunrise (05-08-2015), diodelphi (02-01-2015), ESBjiujitsu (06-08-2012), Fly Guy (06-08-2012), FLYFISHR (07-04-2014), FT_86_SM_GP (05-26-2015), gonzo (09-30-2012), Guff (06-09-2013), Hawk77FT (06-16-2013), isolato (09-06-2015), Jayp (06-07-2012), Jyn (02-05-2015), lazyluka (09-10-2013), LeeMaster (11-07-2012), Lonewolf (07-05-2012), lordtakuban (07-05-2012), mattles (06-07-2012), MattR (06-08-2012), MaXimus (11-22-2012), Mikem53 (05-02-2013), MyGT86Yas (01-06-2018), SirBrass (04-18-2014), sobrz (04-22-2016), Spartan65 (12-04-2012), StarsGarrador (07-05-2012), stevo_12v (10-13-2012), subwaynm (12-15-2013), Symbiont (06-08-2012), tonytduc (06-11-2013), TPO (06-17-2012), ts87 (12-15-2013), Tyrant (04-29-2015), whataboutbob (01-19-2015), xpicer (07-12-2012), xuimod (02-01-2015), XxFooManDrewxX (09-11-2015)
Old 06-07-2012, 05:52 PM   #2
Zaneman
Senior Member
 
Join Date: Mar 2012
Drives: 2013 BRZ limited
Location: Portland
Posts: 212
Thanks: 23
Thanked 64 Times in 47 Posts
Mentioned: 9 Post(s)
Tagged: 0 Thread(s)
Rockin. From the community to you. Thank you!
Zaneman is offline   Reply With Quote
Old 06-07-2012, 06:25 PM   #3
Zoomie
Senior Member
 
Join Date: May 2012
Drives: VW R32
Location: Here, sometimes there.
Posts: 127
Thanks: 17
Thanked 45 Times in 18 Posts
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Excellent! thank you!:happy0180:
Zoomie is offline   Reply With Quote
Old 06-08-2012, 08:48 AM   #4
MattR
Running in the 90s
 
MattR's Avatar
 
Join Date: Apr 2012
Drives: 2014 Scion FR-S Monogram
Location: Wilmington, NC
Posts: 286
Thanks: 359
Thanked 89 Times in 63 Posts
Mentioned: 3 Post(s)
Tagged: 0 Thread(s)
Big thanks guys! These guides will be a massive help to myself and others.

GrimmSpeed
__________________
藤原とうふ店(自家用)
MattR's Tofu Runner
MattR is offline   Reply With Quote
Old 06-08-2012, 01:36 PM   #5
DarrenDriven
NW Region Moderator
 
DarrenDriven's Avatar
 
Join Date: Mar 2010
Drives: FR-S No More
Location: Portland OR
Posts: 5,156
Thanks: 1,134
Thanked 3,182 Times in 1,091 Posts
Mentioned: 300 Post(s)
Tagged: 4 Thread(s)
Garage
Added this to the DIR Directory:
http://www.ft86club.com/forums/showthread.php?t=7365
DarrenDriven is offline   Reply With Quote
The Following User Says Thank You to DarrenDriven For This Useful Post:
whataboutbob (01-19-2015)
Old 06-08-2012, 03:11 PM   #6
ESBjiujitsu
MUST HAVE MORE 86 ! ! !
 
ESBjiujitsu's Avatar
 
Join Date: Apr 2012
Drives: Mazdaspeed 6 2.3 AWD Turbo
Location: Charlotte, North Carolina
Posts: 858
Thanks: 993
Thanked 232 Times in 131 Posts
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Garage
you guys are too good!!!
__________________
WISH LIST: Whiteout FRS- Bronze 18' race rims, Cooper Zeon RS3-S tires,
Cusco Coilovers, Cusco 6 point cage, CF Lip spoiler, CF F1 Mirrors, HKS GT-86 SC

92 carmy -> 86 corolla-> Honda S2000 -> Audi TT -> Mazdaspeed6 -> NEXT UP TOYOTA FT-86!!!!
ESBjiujitsu is offline   Reply With Quote
Old 06-08-2012, 04:51 PM   #7
punchdrunkjuice
Senior Member
 
punchdrunkjuice's Avatar
 
Join Date: May 2012
Drives: haha, 2000 Subaru Impreza L wagon
Location: Indianapolis
Posts: 144
Thanks: 151
Thanked 43 Times in 32 Posts
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Garage
sticky this
__________________
Past: 1992 Eclipse GSX (16g turbo) DEAD 1994 Integra (Ls/VTEC) DEAD 2004 Honda 600RR SOLD 2005 Rx-8 (Shinka Edition) SOLD 2013 Scion FR-S Whiteout SOLD
Present: 2001 Subaru Impreza L wagon Snow Sleigh 2013 Scion 10SERIES Silver Ignition Current

punchdrunkjuice is offline   Reply With Quote
Old 07-05-2012, 10:34 AM   #8
StarsGarrador
Gangnam Style Guru
 
StarsGarrador's Avatar
 
Join Date: Apr 2012
Drives: Suzuki GSXF650, WRB BRZ
Location: Franklin, TN
Posts: 526
Thanks: 463
Thanked 114 Times in 79 Posts
Mentioned: 3 Post(s)
Tagged: 0 Thread(s)
Iloveyou
__________________
StarsGarrador is offline   Reply With Quote
Old 07-12-2012, 05:01 AM   #9
jenwhite
Banned
 
Join Date: Jul 2012
Drives: toyota corolla
Location: Houston TX
Posts: 16
Thanks: 0
Thanked 0 Times in 0 Posts
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
very helpful guide... thanks for sharing
jenwhite is offline   Reply With Quote
Old 08-24-2012, 06:44 PM   #10
was385
Senior Member
 
Join Date: May 2012
Drives: MT WRB BRZ Limited, 2007 911s
Location: CT
Posts: 812
Thanks: 218
Thanked 379 Times in 181 Posts
Mentioned: 9 Post(s)
Tagged: 0 Thread(s)
Alright, so I've gotten almost everything off and I only have the crosspipe to go. I have one of the bolts connecting it to the manifold off and got about half way through on the other and now it will not budge (and the nut is starting to strip). Anyone have any advice?
was385 is offline   Reply With Quote
Old 09-25-2012, 07:37 PM   #11
gonzo
Senior Member
 
Join Date: Jul 2012
Drives: frs
Location: Cali
Posts: 378
Thanks: 355
Thanked 54 Times in 43 Posts
Mentioned: 2 Post(s)
Tagged: 0 Thread(s)
Quote:
Originally Posted by was385 View Post
Alright, so I've gotten almost everything off and I only have the crosspipe to go. I have one of the bolts connecting it to the manifold off and got about half way through on the other and now it will not budge (and the nut is starting to strip). Anyone have any advice?
I think u can try banging it or buying that spray thatll loosen it up. maybe some wd40? or some kind of lube? (lol)



Do any of these bolts have to be torqued a certain amount? should i just tighten it as much as i can by hand? have a torque wrench available but didnt see any number on here
gonzo is offline   Reply With Quote
Old 01-17-2013, 11:11 PM   #12
Jacob G.
Member
 
Jacob G.'s Avatar
 
Join Date: Jul 2012
Drives: '13 Scion FR-S Whiteout
Location: Tallahassee, FL
Posts: 60
Thanks: 13
Thanked 9 Times in 9 Posts
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Garage
Quote:
Originally Posted by gonzo View Post
Do any of these bolts have to be torqued a certain amount? should i just tighten it as much as i can by hand? have a torque wrench available but didnt see any number on here
Anyone have an answer? I tried looking in the owner's manual but didn't see anything at a glance
Jacob G. is offline   Reply With Quote
Old 01-18-2013, 12:43 AM   #13
gonzo
Senior Member
 
Join Date: Jul 2012
Drives: frs
Location: Cali
Posts: 378
Thanks: 355
Thanked 54 Times in 43 Posts
Mentioned: 2 Post(s)
Tagged: 0 Thread(s)
Quote:
Originally Posted by Jacob G. View Post
Anyone have an answer? I tried looking in the owner's manual but didn't see anything at a glance
just tighten them by hand, but dont go extremely tight or they WILL break. trust me I know from personal experience
gonzo is offline   Reply With Quote
Old 03-03-2013, 07:42 PM   #14
rbizzle004
Senior Member
 
Join Date: Nov 2012
Drives: BRZ
Location: WI
Posts: 121
Thanks: 14
Thanked 18 Times in 17 Posts
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quote:
Originally Posted by gonzo View Post
just tighten them by hand, but dont go extremely tight or they WILL break. trust me I know from personal experience
Yep I just learned that lesson from trying to tighten down the spring bolt on the mid pipe and front pipe. Now I have to rig it and hope the Subaru dealership have some on hand tomorrow.
rbizzle004 is offline   Reply With Quote
 
Reply

Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump

Similar Threads
Thread Thread Starter Forum Replies Last Post
Exhaust tip removal Draco-REX Cosmetic Modification (Interior/Exterior/Lighting) 97 05-27-2017 05:50 PM
T1R exhaust for the FRS/BRZ ! AJ PwR Engine, Exhaust, Transmission 57 06-22-2013 10:39 PM
AVO Exhaust Blaaaack-BRZ Engine, Exhaust, Transmission 22 10-16-2012 11:28 PM
HKS Exhaust 01s0uljah Engine, Exhaust, Transmission 1 05-18-2012 09:15 AM
Exhaust system: dual or single KiingDavid Engine, Exhaust, Transmission 163 05-04-2012 01:33 AM


All times are GMT -4. The time now is 01:21 PM.


Powered by vBulletin® Version 3.8.11
Copyright ©2000 - 2021, vBulletin Solutions Inc.
User Alert System provided by Advanced User Tagging v3.3.0 (Lite) - vBulletin Mods & Addons Copyright © 2021 DragonByte Technologies Ltd.

Garage vBulletin Plugins by Drive Thru Online, Inc.