EXHAUST SYSTEM

B ENGINE

SECTION

EXHAUST SYSTEM

EX

EX

CONTENTS
EXHAUST SYSTEM .............................................. ..... 2 Checking Exhaust System .................................. ..... 2 Removal and Installation ..................................... ..... 2 REMOVAL ........................................................ ..... 4 INSTALLATION ................................................ ..... 4 INSPECTION AFTER INSTALLATION ............ ..... 4 SERVICE DATA AND SPECIFICATIONS (SDS) ... ..... 5 Tightening Torque ................................................ ..... 5

EX-1

EXHAUST SYSTEM EXHAUST SYSTEM Checking Exhaust System

Check exhaust pipes, muffler and mounting for improper attachment, leaks, cracks, damage or deterioration.
PFP:20100
EBS008JM

SMA211A

Removal and Installation

EBS008JN

CAUTION: G Be sure to use genuine exhaust system parts or equivalents which are specially designed for heat resistance, corrosion resistance, and shape. G Perform the operation with the exhaust system fully cooled down because the system is still hot just after the engine stops. G Be careful not to cut your hand on the insulator edge.

EX-2

EXHAUST SYSTEM
KA24DE
A

EX

L
PBIC0507E

1. 4. 7.

Mounting rubber Mounting rubber Bracket

2. 5. 8.

Bracket Gasket Ring gasket

3. 6. 9.

Bracket Three-way catalyst Exhaust front tube

10. Insulator 13. Main muffler

11. Stud bolt

12. Bracket

EX-3

EXHAUST SYSTEM
ZD30DD

PBIC0405E

1. 4. 7.

Mounting rubber Mounting rubber Exhaust front tube

2. 5. 8.

Bracket Bracket Bracket

3. 6. 9.

Bracket Ring gasket Main muffler

REMOVAL
1. 2.
G G G

Remove rear side under cover. Disconnect each joint and mounting. Following instructions below, install in reverse order of removal. Always replace exhaust gaskets with new ones when reassembling. If the insulator is badly deformed, repair or replace it. If deposits such as mud pile up on the insulator, remove them. When installing the insulator, avoid large gaps or interference between the insulator and each exhaust pipe. Remove remaining gasket material from the sealing surface of each connection. Connect them securely to avoid gas leakage. Temporarily tighten mounting nuts on the exhaust manifold side and mounting bolts on the vehicle side. Check each part for abnormal interference, and then tighten them to the specified torque. When installing each clamp on insulator, align the protrusion on the insulator with the clamp hole if provided. When installing each mounting rubber, avoid twisting or abnormal extension in up/down and right/left directions. With the engine running, check exhaust tube joints for gas leakage and unusual noises.

INSTALLATION

INSPECTION AFTER INSTALLATION

G

EX-4

SERVICE DATA AND SPECIFICATIONS (SDS) SERVICE DATA AND SPECIFICATIONS (SDS) Tightening Torque
KA24DE Between exhaust manifold and exhaust front tube Between exhaust front tube and three-way catalyst Between three-way catalyst and main muffler Exhaust front tube mounting bracket (Front tube side) (Vehicle side) Main muffler mounting bracket (Bolt) (Nut) ZD30DD Between exhaust manifold and exhaust front tube Between exhaust front tube and main muffler Exhaust front tube mounting bracket (Front tube side) (Vehicle side) Main muffler mounting bracket (Bolt) (Nut) 51.0 - 64.7 (5.2 - 6.6, 38 - 47) 43.1 - 54.9 (4.4 - 5.6, 32 - 40) 43.1 - 54.9 (4.4 - 5.6, 32 - 40) 25.5 - 33.3 (2.6 - 3.4, 19 - 24) 12.7 - 15.7 (1.3 - 1.6, 10 - 11) 12.7 - 15.7 (1.3 - 1.6, 10 - 11) 14.7 - 18.6 (1.5 - 1.9, 11 - 13) 51.0 - 64.7 (5.2 - 6.5, 38 - 47) 25.5 - 33.3 (2.6 - 3.4, 19 - 24) 25.5 - 33.3 (2.6 - 3.4, 19 - 24) 12.7 - 15.7 (1.3 - 1.6, 10 - 11) 12.7 - 15.7 (1.3 - 1.6, 10 - 11) 14.7 - 18.6 (1.5 - 1.9, 11 - 13)
PFP:00030

A
EBS00AMN

Unit: Nm (kg-m, ft-lb)

EX

EX-5

SERVICE DATA AND SPECIFICATIONS (SDS)

EX-6