EXHAUST SYSTEM

B ENGINE
A

SECTION

EXHAUST SYSTEM

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

PFP:20100
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

Mounting rubber

Bracket

Bracket

Mounting rubber

Gasket

Three-way catalyst

Bracket

Ring gasket

Exhaust front tube

10 Insulator

11 Stud bolt

12 Bracket

13 Main muffler

EX-3

EXHAUST SYSTEM
ZD30DD

PBIC0405E

Mounting rubber

Bracket

Bracket

Mounting rubber

Bracket

Ring gasket

Exhaust front tube

Bracket

Main muffler

REMOVAL
1.
2.

Remove rear side under cover.

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 provided.
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)
Tightening torque

PFP:00030

A
EBS00AMN

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

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
12.7 - 15.7 (1.3
12.7 - 15.7 (1.3
14.7 - 18.6 (1.5

- 3.4, 19 - 24)
- 1.6, 10 - 11)
- 1.6, 10 - 11)
- 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
12.7 - 15.7 (1.3
12.7 - 15.7 (1.3
14.7 - 18.6 (1.5

- 3.4, 19 - 24)
- 1.6, 10 - 11)
- 1.6, 10 - 11)
- 1.9, 11 - 13)

EX

EX-5

SERVICE DATA AND SPECIFICATIONS (SDS)

EX-6