ENGINE EXHAUST 6F-1

SECTION 6F
ENGINE EXHAUST

CONTENTS

PAGE
General Description........................................................................................................ 6F- 2
Service Precaution ......................................................................................................... 6F- 4
Exhaust Pipe ................................................................................................................... 6F- 5
Exhaust pipe and Associated parts.......................................................................... 6F- 5
Removal ...................................................................................................................... 6F- 5

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Installation .................................................................................................................. 6F- 6
Inspection ................................................................................................................... 6F- 6
Front Exhaust Pipe ......................................................................................................... 6F- 7
Front Exhaust Pipe and Associated Parts ............................................................... 6F- 7
Removal ...................................................................................................................... 6F- 7
Installation .................................................................................................................. 6F- 7
Mid Pipe ........................................................................................................................... 6F- 8
Mid Pipe and associated Parts ................................................................................. 6F- 8
Removal ...................................................................................................................... 6F- 8
Installation .................................................................................................................. 6F- 8
Catalytic Converter (If applicable) ................................................................................. 6F- 9
Catalytic Converter and Associated Parts ............................................................... 6F- 9
Removal ...................................................................................................................... 6F- 9
Installation .................................................................................................................. 6F- 9
3 way Catalytic Converter System ............................................................................ 6F- 10
Exhaust Silencer............................................................................................................. 6F- 12
Exhaust Silencer and Associated Parts................................................................... 6F- 12
Removal ...................................................................................................................... 6F- 12
Installation .................................................................................................................. 6F- 13
Main Data and Specifications ........................................................................................ 6F- 14
Torque Specification.................................................................................................. 6F- 15
6F-2 ENGINE EXHAUST

General Description

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RTW46AMF000501
 ENGINE EXHAUST 6F-3

When inspecting or replacing exhaust system components,

make sure there is adequate clearance from all points on the
underbody to prevent overheating the floor pan and possible
damage to the passenger compartment insulation and trim
materials.
Check complete exhaust system and nearby body areas and
rear compartment lid for broken, damaged, missing or
mispositioned parts, open seams, holes, loose connections or
other deterioration which could permit exhaust fumes to seep
into the rear compartment or passenger compartment. Dust or
water in the rear compartment may be an indication of a
problem in one of these areas. Any faulty areas should be
corrected immediately.

Hangers
Various types of hangers are used to support exhaust
system(s). These include conventional rubber straps, rubber
rings, and rubber blocks.
The installation of exhaust system supports is very important,

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as improperly installed supports can cause annoying vibrations
which can be difficult to diagnose.

Three Way Catalytic Converter (If applicable)

The three way catalytic converter is an emission control device
added to the exhaust system to reduce pollutants from the
exhaust gas stream.

CAUTION: The catalytic converter requires the use of

unleaded fuel only.
Periodic maintenance of the exhaust system is not required. If
the vehicle is raised for other service, it is advisable to check
the condition of the complete exhaust system.
A dual bed monolith catalytic converter is used in combination
with three way catalytic converter.
Catalytic Types:
Three way (Reduction/Oxidation) catalyst
The catalyst coating on the three way (reduction) converter
contains platinum and rhodium which lowers the levels of
nitrous oxide (NOx) as well as hydrocarbons (HC) and carbon
monoxide (Co).

Gasket
The gasket must be replaced whenever a new exhaust pipe,
muffler or catalytic converter is installed.
6F-4 ENGINE EXHAUST

Service Precaution
CAUTION:
Always use the correct fastener in the proper location.
When you replace a fastener, use ONLY the exact part
number for that application. ISUZU will call out those
fasteners that require a replacement after removal. ISUZU
will also call out the fasteners that require thread lockers
or thread sealant. UNLESS OTHERWISE SPECIFIED, do
not use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or fastener
joint interfaces. Generally, such coatings adversely affect
the fastener torque and the joint clamping force, and may
damage the fastener. When you install fasteners, use the
correct tightening sequence and specifications. Following
these instructions can help you avoid damage to parts
and systems.

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 ENGINE EXHAUST 6F-5

Exhaust Pipe
Exhaust Pipe and Associated parts

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RTW46FLF000401

Removal
(2.4L)
CAUTION
When you remove or install the front exhaust pipe, make
sure not to damage the fuel evaporative pipe.

1. Damper rubber
2. Exhaust silencer
3. Mid pipe
4. Damper rubber
5. Front exhaust pipe fixing nut
6. Catalytic converter (If applicable)
7. Front exhaust pipe
6F-6 ENGINE EXHAUST

Installation
To install, follow the removal steps in the reverse order.

Important - Installation
1. Front Exhaust Pipe Flange Nut
Connect the exhaust pipe to the exhaust manifold.
Front exhaust pipe to manifold nut.
Torque

N×m (kgf×m)
28 (2.9)

Inspection
Make the necessary adjustments, and part replacements if
excessive wear or damage is discover during inspection.

1. Front Exhaust Pipe

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2. Center Exhaust Pipe and Catalytic Converter Flange Nut
3. Exhaust Pipe Damper Rubber
4. Exhaust Silencer with Rear Exhaust Pipe

Check the pipes for for corrosion, cracking , damage or

misalignment and repair if required.
Check the damper rubber for deterioration or damage and
repair if required.
 ENGINE EXHAUST 6F-7

Front Exhaust Pipe (W/O Catalytic

Converter)
Front Exhaust Pipe and Associated Parts

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RTW46F000101

Legend
1. Front Exhaust Pipe Fixing Nuts
2. Front Exhaust Pipe
3. Mid Exhaust Pipe Fixing Nuts

Removal
(2.4L)
1. Disconnect battery ground cable.
2. Raise the vehicle and support with suitable safety stands.
3. Remove the front exhaust pipe fixing nuts (1).
4. Remove mid pipe fixing nuts (3).
5. Remove front exhaust pipe (2).

Installation
1. Install front exhaust pipe (2) and tighten four nuts (1).
Torque:
Nuts: 28 N××m (2.9 kgf××m)
2. Tighten two nuts (3).
Torque: 43 N××m (4.4 kgf××m)
6F-8 ENGINE EXHAUST

Mid Pipe
Mid Pipe and Associated Parts

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RTW46FSF000201

Legend
1. Mid Exhaust Pipe
2. Mid Exhaust Pipe Fixing Nuts
3. Exhaust Silencer Fixing Nuts

Removal
(2.4L)
1. Disconnect battery ground cable.
2. Raise the vehicle and support with suitable safety stands.
3. Remove mid pipe fixing nuts (2).
4. Remove exhaust silencer fixing nuts (3).
5. Remove the pipe.

Installation
1. Install mid exhaust pipe (1) and tighten four fixing nuts
(2)(3) to the specified torque:
Torque:
Fixing nuts: 43 N××m (4.4 kgf××m)
 ENGINE EXHAUST 6F-9

Catalytic Converter (If applicable)

Catalytic Converter and Associated Parts

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RTW46FSF000301

Legend
1. Catalytic Converter
2. O2 Sensor Converter
3. Front Pipe Fixing Nuts
4. Mid Pipe Fixing Nuts

Removal
(2.4L)
1. Disconnect battery ground cable.
2. Raise the vehicle and support with suitable safety stands.
3. Remove front pipe fixing nuts (3).
4. Remove mid pipe fixing nuts (4).
5. Remove the O2 sensor connector (2).
6. Remove the front exhaust pipe with catalytic converter (1).

Installation
1. Install Catalytic Converter (1) and tighten four to the
specified torque:
Torque:
Fixing nuts: 28 N××m (2.9 kgf××m)
2. Tight two nuts (4)
Torque:
Nuts: 43 N××m (4.4 kgf××m)
3. Connect the O2 sensor connector (2).
6F-10 ENGINE EXHAUST

3 WAY CATALYTIC CONVERTER

SYSTEM (If applicable)

N2

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Inspection
Make the necessary adjustments, and part replacements if
excessive or damage is discovered during inspection.

Exhaust Pipe Assembly

1. Check connections for looseness or damage.
2. Check clamps for weakness, crack, or damage.

Catalytic Converter
Check for dents or damage.
If any part of the converter is damaged or dented, repair or
replace it.

Removal
1. Jack up the vehicle.
2. Check that the converter is cool.
3. Remove the bolts at the front and rear of the converter.
4. Remove the converter and gaskets.
 ENGINE EXHAUST 6F-11

(2.4L model) Installation

1. Place new gaskets on the converter front and rear pipes,
and connect the converter to the exhaust pipes.
2. Tighten the bolts with the specified torque.
3. Reinstall the bracket bolts and tighten them.

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6F-12 ENGINE EXHAUST

Exhaust Silencer
Exhaust Silencer and Associated Parts

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RTW46FMF000701

Legend
1. Exhaust Silencer
2. Exhaust Silencer Fixing Nuts
3. Rubber

Removal
(2.4L)
1. Disconnect battery ground cable.
2. Raise the vehicle and support with suitable safety stands.
3. Remove the damper rubber and nut (2)(3).
4. Remove exhaust silencer (1).
 ENGINE EXHAUST 6F-13

Installation
(2.4L)
1. Install the exhaust silencer and tighten two nuts and the
damper rubbers.

Torque:
Bolts: 43 N××m (4.4 kgf××m)

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6F-14 ENGINE EXHAUST

Main Data and Specifications

Exhaust system
Pipe outside diameter ✕ thickness
Front pipe mm(in) 44.5 ✕ 1.5 (1.75✕0.059)
Middle pipe mm(in) 50.8 ✕ 1.5 (2.00 ✕ 0.059)
Rear pipe mm(in) 50.8 ✕ 1.5 (2.0 ✕ 0.059)

Silencer
Type Circular section-shell construction
of triple; double skin and end plates, internal
construction of baffles
and perforated tubes.

Number of suspension points 4

Type Rubber
Catalytic converter type (If applicable) Three way Catalytic Converter

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 ENGINE EXHAUST 6F-15

Main Data and Specifications

Torque Specification

Nžm (kgfžm)

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43N⋅m (4.4 kgf⋅m)

43N⋅m (4.4 kgf⋅m)

6F-16 ENGINE EXHAUST

MEMO

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