1. Introduction
This manual provides essential information for the proper installation, operation, and maintenance of your HKS 3203-EX020 Hi-Power Exhaust System. This product is designed specifically for the Lexus IS300 models manufactured between 2001 and 2005. Please read this manual thoroughly before proceeding with installation or use to ensure safety and optimal performance.
2. Safety Information
- Always wear appropriate personal protective equipment, including safety glasses and gloves, when working on your vehicle.
- Ensure the vehicle is securely supported on jack stands or a lift before working underneath it. Never rely solely on a jack.
- Allow the engine and exhaust system to cool completely before beginning installation to prevent burns.
- Exercise caution when handling exhaust components, as edges may be sharp.
- It is recommended that installation be performed by a qualified professional to ensure correct fitment and safety.
- Proposition 65 Warning: This product may contain chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.
3. Package Contents
Verify that all components are present and undamaged before beginning installation:
- HKS Hi-Power Exhaust Dual Rear Sections (Left and Right)
- Associated mounting hardware (e.g., bolts, nuts, washers, hangers)
If any items are missing or damaged, please contact your retailer or HKS customer support.
4. Setup and Installation
The following steps outline a general procedure for installing the HKS Hi-Power Exhaust system. Specific details may vary, and professional installation is highly recommended.
4.1 Tools and Materials Required
- Socket wrench set
- Open-end wrench set
- Torque wrench
- Penetrating oil (optional, for rusted bolts)
- Exhaust gasket (if not included or replacing old one)
- Vehicle lift or jack stands
- Safety glasses and gloves
4.2 Installation Steps
- Prepare the Vehicle: Park the vehicle on a level surface. Engage the parking brake. If using a jack, lift the rear of the vehicle and secure it with jack stands. Ensure the vehicle is stable.
- Allow Cooling: Ensure the existing exhaust system is completely cool to the touch before proceeding.
- Remove Existing Rear Sections: Locate the connection points of the factory rear exhaust sections. Apply penetrating oil to any rusted bolts or nuts. Carefully unbolt and detach the existing rear mufflers and piping from the mid-pipe or catalytic converter. Support the exhaust to prevent it from falling.
- Remove Exhaust Hangers: Carefully remove the factory exhaust hangers from the rubber isolators on the vehicle chassis.
- Install HKS Exhaust: Begin by loosely fitting the HKS Hi-Power Exhaust rear sections into position. Connect the new exhaust to the mid-pipe using new gaskets and bolts (if applicable).
- Attach Hangers: Slide the HKS exhaust hangers into the factory rubber isolators on the vehicle chassis.
- Align and Tighten: Once all sections are loosely in place and aligned, ensure proper clearance from the vehicle's undercarriage and suspension components. Gradually tighten all bolts and nuts, working from the front connection points towards the rear. Do not overtighten.
- Final Inspection: After tightening, visually inspect all connections for proper seating and ensure there are no leaks. Check for any contact between the exhaust system and the vehicle body.
- Lower Vehicle: Carefully lower the vehicle from the jack stands or lift.
5. Operating Information
The HKS Hi-Power Exhaust system is designed to enhance the sound and performance characteristics of your Lexus IS300. Upon initial installation, a brief break-in period may be observed where the exhaust sound may slightly change as carbon deposits form. The system is known for producing a deep, resonant tone without excessive raspiness, providing a refined yet sporty exhaust note.
Regular driving conditions will allow the exhaust to settle. Pay attention to any unusual noises or vibrations, especially during the first few drives after installation.
6. Maintenance
To ensure the longevity and continued performance of your HKS Hi-Power Exhaust system, periodic maintenance is recommended:
- Regular Inspection: Periodically inspect the entire exhaust system for any signs of damage, corrosion, loose connections, or worn hangers. Check for cracks, dents, or excessive rust.
- Tighten Connections: Over time, vibrations can cause bolts and nuts to loosen. Periodically check and re-tighten all connections to the manufacturer's recommended torque specifications.
- Clean Exhaust Tips: The polished exhaust tips can be cleaned with a non-abrasive metal polish to maintain their appearance. Avoid harsh chemicals that may damage the finish.
- Hanger Condition: Inspect rubber exhaust hangers for signs of cracking, tearing, or excessive wear. Replace damaged hangers as needed to prevent rattling or misalignment.
7. Troubleshooting
If you encounter any issues with your HKS Hi-Power Exhaust system, refer to the following troubleshooting guide:
| Problem | Possible Cause | Solution |
|---|---|---|
| Rattling or Vibration | Loose connections, exhaust touching chassis, worn hangers | Check and tighten all bolts. Inspect for contact points and adjust alignment. Replace worn hangers. |
| Exhaust Leak | Improperly seated gasket, loose flange, crack in piping | Inspect all gaskets and flanges. Re-tighten connections. If a crack is found, professional repair or replacement may be necessary. |
| Unusual Noise (e.g., metallic clanking) | Loose internal baffle, foreign object in muffler, heat shield contact | Inspect the muffler for internal damage. Check for any loose heat shields or debris. |
If the issue persists after attempting these solutions, it is advisable to consult with a professional automotive technician.
8. Specifications
| Brand | HKS |
| Model Number | 3203-EX020 |
| Application | Lexus IS300 (2001-2005) |
| Type | Hi-Power Exhaust (Dual Rear Sections Only) |
| Item Weight | 39.9 pounds (approx.) |
| Product Dimensions (L x W x H) | 60 x 17.99 x 12 inches (approx.) |
| UPC | 816532024625 |
9. Warranty and Support
For information regarding the product warranty, please refer to the official HKS website or contact your authorized HKS dealer. Warranty terms and conditions may vary by region and product.
For technical assistance, installation queries, or to report any issues, please contact HKS customer support directly through their official channels. Ensure you have your product model number (3203-EX020) and purchase details available when seeking support.
