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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
.
H
I
J
K
L
M
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.
H
I
J
K
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M
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
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