ENGINE

SECTION
EXHAUST SYSTEM
EX EX

CONTENTS
SERVICE INFORMATION ............................ 2
PREPARATION ................................................... 2
Special Service Tool ................................................. 2
Commercial Service Tool .......................................... 2
EXHAUST SYSTEM ............................................ 3
E
Checking Exhaust System ........................................ 3 F
Component (VQ Engine Models) .............................. 3
Component (YD Engine Models without DPF) ......... 4
Removal and Installation .......................................... 4 G
Component (YD Engine Models with DPF) .............. 6
Removal and Installation (Models with DPF) ............ 7
H

EX-1
 PREPARATION
< SERVICE INFORMATION >
SERVICE INFORMATION
PREPARATION
Special Service Tool INFOID:0000000002980048

Tool number
Description
Tool name
KV10114400 Loosening or tightening heated oxygen sen-
Heated oxygen sensor wrench sor 2 and air fuel ratio sensor 1 and heated ox-
ygen sensor 2
For 22 mm (0.87 in) width hexagon nut

S-NT636

Commercial Service Tool INFOID:0000000002980049

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

EX-2
 EXHAUST SYSTEM
< SERVICE INFORMATION >
EXHAUST SYSTEM
A
Checking Exhaust System INFOID:0000000001475411

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
Component (VQ Engine Models) INFOID:0000000001475412

P
JPBIA1361GB

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

4. Gasket 5. Exhaust front tube (right bank) 6. Heated oxygen sensor 2 (bank 1)
Three way catalyst (manifold) (right
7. Ring gasket 8. 9. Ring gasket
bank)

EX-3
 EXHAUST SYSTEM
< SERVICE INFORMATION >
Three way catalyst (manifold) (left
10. 11. Heated oxygen sensor 2 (bank 2) 12. Exhaust front tube (left bank)
bank)
13. Ground cable
A. Do not loosen these nuts. B. To exhaust manifold (right bank) C. To exhaust manifold (left bank)

• Refer to GI-9, "Component" for symbol marks in the figure.

Component (YD Engine Models without DPF) INFOID:0000000001475413

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-9, "Component" for symbol marks in the figure.

Removal and Installation INFOID:0000000001475414

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.

EX-4
 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

EX-5
 EXHAUST SYSTEM
< SERVICE INFORMATION >
Component (YD Engine Models with DPF) INFOID:0000000001475415

JPBIA1315GB

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

Differential exhaust pressure sensor
4. 5. Gasket 6. DPF cover
tube
7. Bracket 8. Mounting rubber 9. Bracket
Front exhaust gas temperature sen- Differential exhaust pressure sensor
10. 11. 12. Ring gasket
sor tube
13. Catalyst 14. Exhaust front tube 15. Gasket
16. DPF 17. Bracket 18. Mounting rubber
19. Bracket 20. Sensor harness bracket 21. Bracket

EX-6
 EXHAUST SYSTEM
< SERVICE INFORMATION >
Rear exhaust gas temperature sen-
22. 23. Air fuel ratio sensor 1 24. Differential exhaust pressure sensor
sor A
Differential exhaust pressure sensor
25.
tube
A. Do not loosen these nuts B. To exhaust outlet EX
• Refer to GI-9, "Component" for symbol marks in the figure.
Removal and Installation (Models with DPF) INFOID:0000000001475416
C
CAUTION:
• Be sure to use genuine exhaust system parts or equivalents which are specially designed for heat
resistance, corrosion resistance and shape. D
• 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. E
• If DPF warning lamp turns on, refer to EC-1733, "Description".
• Perform particulate matter accumulation value resetting when DPF is replaced with new one. Refer
to EC-1315, "DPF Data Clear".
• Perform A/F sensor leaning value clear when air fuel ratio sensor 1 is replaced. Refer to EC-1314, "A/ F
F Sensor Learning Value Clear".
REMOVAL
G
• After applying penetrative lubricant to the mounting nuts, check for the penetration of the lubricant, and then
loosen the bolts and nuts to remove.
• Separate each connection as necessary.
CAUTION: H
• Be careful not to impact or damage exhaust gas temperature sensors.
• Never disassemble or damage differential exhaust pressure sensor.
• Never deform differential exhaust pressure sensor tubes. I
• Never disassemble, impact or damage DPF.
• Never remove exhaust gas temperature sensors except for replacing with new parts.
- Remove air fuel ratio sensor 1 (2) using heated oxygen sensor
wrench [SST: KV10114400] (A). J

1 : Catalyst
CAUTION: K
• Be careful not to damage air fuel ratio sensor 1.
• Discard any air fuel ratio sensor 1 which has been dropped
onto a hard surface such as a concrete floor. Replace a new L
one.

PBIC4885E
M
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
N
• Always replace exhaust gaskets and seal bearings with new ones when reassembling.
• 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. O
• Remove deposits 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
P
side. Check each part for unusual interference, and then tighten them to the specified torque.
• When installing each mounting rubber, avoid twisting or unusual extension in up/down and right/left
directions.
• Perform particulate matter accumulation value resetting when DPF is replaced with new one. Refer
to EC-1315, "DPF Data Clear".
Air Fuel Ratio Sensor 1

EX-7
 EXHAUST SYSTEM
< SERVICE INFORMATION >
• Install air fuel ratio sensor 1 in the original position.

1 : DPF
2 : Air fuel ratio sensor 1
3 : Rear exhaust gas temperature sensor
4 : Air fuel ratio sensor harness bracket
A : View A
: Vehicle front

CAUTION:
• Perform A/F sensor leaning value clear when air fuel ratio
sensor 1 is replaced. Refer to EC-1314, "A/F Sensor Learning
Value Clear".
• Before installing a new air fuel ratio sensor, clean catalyst
thread using oxygen sensor thread cleaner (commercial ser-
vice tool) and apply anti-seize lubricant (commercial service
tool).
• Never over torque air fuel ratio sensor. Doing so may cause
damage to air fuel ratio sensor 1, resulting in the “MIL” com-
ing on.

PBIC4884E

Exhaust Gas Temperature Sensor

• Install exhaust gas temperature sensor in the original position.
CAUTION:
Before installing a new exhaust gas temperature sensor, clean catalyst thread.
• Install referring to the following if the installation positions cannot be identified.

Harness connector color

Front exhaust temperature sensor : White
Rear exhaust temperature sensor : Black
• Install rear exhaust gas temperature sensor harness as shown in
the figure.

1 : DPF
2 : Air fuel ratio sensor 1
3 : Rear exhaust gas temperature sensor
4 : Air fuel ratio sensor harness bracket
A : View A
: Vehicle front

CAUTION:
Never install rear exhaust gas temperature sensor harness
tensely.

PBIC4884E

Differential Exhaust Pressure Sensor

Install differential exhaust pressure sensor and related parts as shown in the figure.
CAUTION:
EX-8
 EXHAUST SYSTEM
< SERVICE INFORMATION >
• Never disassemble or damage differential exhaust pressure sensor.
• Never deform differential exhaust pressure sensor tubes. A
• Clamp shall not run aground on bulge.

EX

PBIC4869E
G
Differential exhaust pressure sensor
1. Differential exhaust pressure sensor 2. Clamp 3.
hose
Differential exhaust pressure sensor Differential exhaust pressure sensor H
4. 5. 6. Clamp
hose tube
Differential exhaust pressure sensor Differential exhaust pressure sensor Differential exhaust pressure sensor
7. 8. 9.
hose tube tube
I
Differential exhaust pressure sensor
10.
hose
A. View A B. View B C. View C
J
D. View D E. View E F. View F
Insertion length of differential ex-
G. View G H. View H I.
haust pressure sensor hose
To differential exhaust pressure sen- To differential exhaust pressure sen- K
J. K. L. Installation of clamps
sor tubes (up to bulge) sor (up to the wall face)
M. Yellow paint N. White paint O. Blue paint
P. Red paint L

INSPECTION AFTER INSTALLATION

• With the engine running, check exhaust tube joints for gas leakage and unusual noises. M
• 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.

EX-9