ENGINE

SECTION
EXHAUST SYSTEM
EX EX

CONTENTS
SERVICE INFORMATION ............................ 2
PREPARATION ................................................... 2
Special Service Tool ................................................. 2
Commercial Service Tool .......................................... 2
E
EXHAUST SYSTEM ........................................... 3 F
Checking Exhaust System ........................................ 3
Components (QR Engine Models) ............................ 3
Components (YD Engine Models) ............................ 4 G
Removal and Installation .......................................... 4

Revision: 2007 September EX-1 D40

 PREPARATION
< SERVICE INFORMATION >
SERVICE INFORMATION
PREPARATION
Special Service Tool INFOID:0000000003293023

Tool number
Description
Tool name
KV10114400 Loosening or tightening heated oxygen sen-
Heated oxygen sensor wrench sor 2
For 22 mm (0.87 in) width hexagon nut

S-NT636

Commercial Service Tool INFOID:0000000003293024

Tool name Description

Oxygen sensor thread cleaner Reconditioning the exhaust system threads
before installing a new air fuel ratio sensor and
heated oxygen sensor (Use with anti-seize lu-
bricant shown below.)
a : 18 mm (0.71 in) dia. for air fuel ratio sen-
sor 1
b : 12 mm (0.47 in) dia. for exhaust gas tem-
perature sensor
AEM488

Anti-seize lubricant (Permatex 133AR Lubricating oxygen sensor thread cleaning

or equivalent meeting MIL specifica- tool when reconditioning exhaust system
tion MIL-A-907) threads

AEM489

Revision: 2007 September EX-2 D40

 EXHAUST SYSTEM
< SERVICE INFORMATION >
EXHAUST SYSTEM
A
Checking Exhaust System INFOID:0000000003293025

Check exhaust pipes, muffler and mounting for improper attachment, EX

leaks, cracks, damage or deterioration.
• If anything is found, repair or replace damaged parts.
C

SMA211A E
Components (QR Engine Models) INFOID:0000000003293026

P
JPBIA1569GB

1. Mounting rubber 2. Mounting rubber 3. Main muffler

4. Gasket 5. Mounting bracket 6. Mounting rubber
7. Heated oxygen sensor 2 8. Ring gasket 9. Exhaust front tube

Revision: 2007 September EX-3 D40

 EXHAUST SYSTEM
< SERVICE INFORMATION >
10. Mounting rubber 11. Mounting bracket 12. Ground cable
To exhaust manifold and three way
A. Do not loosen these nuts. B.
catalyst

• Refer to GI-7, "Component" for symbol marks in the figure.

Components (YD Engine Models) INFOID:0000000003293027

JPBIA1314GB

1. Mounting rubber 2. Mounting rubber 3. Main muffler

4. Gasket 5. Ground cable 6. Catalyst
7. Ring gasket 8. Exhaust front tube
A. Do not loosen these nuts. B. To exhaust outlet

• Refer to GI-7, "Component" for symbol marks in the figure.

Removal and Installation INFOID:0000000003293028

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 will be hot
just after engine stops.
• Be careful not to cut your hand on the insulator edge.

Revision: 2007 September EX-4 D40

 EXHAUST SYSTEM
< SERVICE INFORMATION >
REMOVAL
Separate each connection as necessary. A
CAUTION:
Never disassemble main muffler at the portion “A” shown in the figure.
INSTALLATION EX
Note the following, and install in the reverse order of removal.
CAUTION:
• Always replace exhaust gaskets and seal bearings with new ones when reassembling. C
• If insulator is badly deformed, repair or replace it. If deposits such as mud pile up on insulator,
remove them.
• When installing insulator avoid large gaps or interference between insulator and each exhaust pipe.
• Remove deposits from the sealing surface of each connection. Connect them securely to avoid gas D
leakage.
• Temporarily tighten mounting nuts on the exhaust manifold side and mounting bolts on the vehicle
side. Check each part for unusual interference, and then tighten them to the specified torque. E
• When installing each mounting rubber, avoid twisting or unusual extension in up/down and right/left
directions.
INSPECTION AFTER INSTALLATION F
• With the engine running, check exhaust tube joints for gas leakage and unusual noises.
• Check to ensure that mounting brackets and mounting rubbers are installed properly and free from undue
stress. Improper installation could result in excessive noise and vibration. G

Revision: 2007 September EX-5 D40