EXHAUST SYSTEM

B ENGINE

EX
SECTION
EXHAUST SYSTEM C

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

EX-1
 EXHAUST SYSTEM

EXHAUST SYSTEM PFP:20100

Checking Exhaust System EBS008JM

Check exhaust pipes, muffler and mounting for improper attachment,

leaks, cracks, damage or deterioration.

SMA211A

Removal and Installation EBS008JN

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

EX-2
 EXHAUST SYSTEM

KA24DE
A

EX

L
PBIC0507E

1 Mounting rubber 2 Bracket 3 Bracket

M
4 Mounting rubber 5 Gasket 6 Three-way catalyst
7 Bracket 8 Ring gasket 9 Exhaust front tube
10 Insulator 11 Stud bolt 12 Bracket
13 Main muffler

EX-3
 EXHAUST SYSTEM

ZD30DD

PBIC0405E

1 Mounting rubber 2 Bracket 3 Bracket

4 Mounting rubber 5 Bracket 6 Ring gasket
7 Exhaust front tube 8 Bracket 9 Main muffler

REMOVAL
1. Remove rear side under cover.
2. Disconnect each joint and mounting.
INSTALLATION
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 pro-
vided.
When installing each mounting rubber, avoid twisting or abnormal extension in up/down and right/left
directions.
INSPECTION AFTER INSTALLATION
With the engine running, check exhaust tube joints for gas leakage and unusual noises.

EX-4
 SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

A
Tightening torque EBS00AMN

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

KA24DE
EX
Between exhaust manifold and exhaust front tube 51.0 - 64.7 (5.2 - 6.6, 38 - 47)
Between exhaust front tube and three-way catalyst 43.1 - 54.9 (4.4 - 5.6, 32 - 40)
Between three-way catalyst and main muffler 43.1 - 54.9 (4.4 - 5.6, 32 - 40)
Exhaust front tube mounting bracket C
(Front tube side) 25.5 - 33.3 (2.6 - 3.4, 19 - 24)
(Vehicle side) 12.7 - 15.7 (1.3 - 1.6, 10 - 11)
Main muffler mounting bracket (Bolt) 12.7 - 15.7 (1.3 - 1.6, 10 - 11)
(Nut) 14.7 - 18.6 (1.5 - 1.9, 11 - 13) D
ZD30DD
Between exhaust manifold and exhaust front tube 51.0 - 64.7 (5.2 - 6.5, 38 - 47)
Between exhaust front tube and main muffler 25.5 - 33.3 (2.6 - 3.4, 19 - 24) E
Exhaust front tube mounting bracket
(Front tube side) 25.5 - 33.3 (2.6 - 3.4, 19 - 24)
(Vehicle side) 12.7 - 15.7 (1.3 - 1.6, 10 - 11)
Main muffler mounting bracket (Bolt) 12.7 - 15.7 (1.3 - 1.6, 10 - 11) F
(Nut) 14.7 - 18.6 (1.5 - 1.9, 11 - 13)

EX-5
SERVICE DATA AND SPECIFICATIONS (SDS)

EX-6