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EXHAUST SYSTEM


B ENGINE

                                                                                                                                                       A




                                                                                             SECTION
                                                                                           EXHAUST SYSTEM
                                                                                                                      EX                               EX



                                                                                                                                                       C


                                                                                                                                                       D


                                                                                                                                                       E
                                                            CONTENTS
PREPARATION .......................................................... 2
                                                                 .          Checking Exhaust System ....................................... 3.         F
 Commercial Service Tools ....................................... 2
                                                                 .          Removal and Installation ......................................... 3
                                                                                                                                             .
EXHAUST SYSTEM .................................................. 3
                                                                 .            REMOVAL ............................................................ 4
                                                                                                                                             .
                                                                              INSTALLATION .................................................... 4
                                                                                                                                             .         G
                                                                              INSPECTION AFTER INSTALLATION ................. 4              .
                                                                           SERVICE DATA AND SPECIFICATIONS (SDS) ....... 5                   .
                                                                            Tightening Torque .................................................... 5
                                                                                                                                             .
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                                                                      EX-1
                           PREPARATION

PREPARATION                                                                 PFP:00002

Commercial Service Tools                                                       ABS002YD



 Tool name                                       Description

 Power tool                                      Loosening nuts and bolts




                                     PBIC0190E




                              EX-2
                                         EXHAUST SYSTEM

EXHAUST SYSTEM                                                                                            PFP:20100
                                                                                                                          A
Checking Exhaust System                                                                                        ABS004SD


Check exhaust pipes, muffler and mounting for improper attachment,
leaks, cracks, damage or deterioration.                                                                                   EX
q   If anything is found, repair or replace damaged parts.

                                                                                                                          C


                                                                                                                          D

                                                                                                            SMA211A

                                                                                                                          E
Removal and Installation                                                                                       ABS004SE


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


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                                                                                                         PBIC2037E

  1.   Mounting rubber              2.   Main muffler mounting bracket   3.   Main muffler
  4.   Ring gasket                  5.   Mounting bracket                6.   Center muffler
  7.   Collar                       8.   Grommet                         9.   Exhaust mounting bracket
  10. Gasket                        11. Exhaust front tube

                                                    EX-3
                                           EXHAUST SYSTEM

REMOVAL
q   Disconnect each joint and mounting with power tool.
q   When removing main muffler, remove main muffler mounting bracket bolts.
INSTALLATION
Note to the following, and install in the reverse order of removal.
q   Tighten main muffler mounting bracket bolts in numerical order
    as shown in the figure.




                                                                                                          PBIC1675E




When reassembling main muffler only.
1. Temporarily tighten connecting flange (A).
2. Move main muffler front / rear / left / right so that clearance
   between tail tube and bumper is even.
3. Tighten connecting flange (A) to the specified torque.
When reassembling center muffler.
1. Temporarily tighten connecting flanges in order of (A) and (B).
2. Move main muffler front / rear / left / right so that clearance
   between tail tube and bumper is even.
3. Tighten connecting flanges in order of (A) and (B) to the speci-
   fied torque.                                                                                          PBIC2104E


When reassembling exhaust front tube.
1. Temporarily tighten connecting flanges of center muffler in order of (B) and (C).
2. Move main muffler front / rear / left / right so that clearance between tail tube and bumper is even.
3. Tighten connecting flanges in order of (B) and (C) to the specified torque.
CAUTION:
q  Always replace exhaust tube gaskets with new ones when reassembling.
q  If heated insulator is badly deformed, repair or replace it. If deposits such as mud pile up on
   heated insulator, remove them.
q  When installing heated insulator avoid large gaps or interference between heated insulator and
   each exhaust pipe.
q  Remove deposits from the sealing surface of each connection. Connect them securely to avoid
   gas leakage.
q  Temporarily tighten mounting nuts on the exhaust manifold side and mounting bolts on the vehi-
   cle side. Check each part for unusual interference, and then tighten them to the specified torque.
q  When installing each mounting rubber, avoid twisting or unusual extension in up/down and right/
   left directions.
INSPECTION AFTER INSTALLATION
q   With engine running, check exhaust tube joints for gas leakage and unusual noises.
q   Make sure that mounting brackets and mounting rubbers are installed properly and free from undue
    stress. Improper installation could result in excessive noise and vibration.
q   Make sure that clearance between tail tube and bumper is even.




                                                     EX-4
                           SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS)                                                                 PFP:00030
                                                                                                                     A
Tightening Torque                                                                                         ABS004SG

                                                                                         Unit: N



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