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EXHAUST SYSTEM

B ENGINE

SECTION
EXHAUST SYSTEM
EX EX

E
CONTENTS
PREPARATION .......................................................... 2
. REMOVAL (MUFFLER CONTROL UNIT) ............ 6 . F
Special Service Tools .............................................. 2
. INSTALLATION .................................................... 6 .
Commercial Service Tools ....................................... 2
. Trouble Diagnoses .................................................. 7 .
EXHAUST SYSTEM .................................................. 3
. WIRING DIAGRAM .............................................. 7 . G
Checking Exhaust System ...................................... 3 . PARTS LOCATION ............................................... 7 .
Removal and Installation ......................................... 3
. INSPECTION OF VALVE OPERATION ............... 8 .
REMOVAL ............................................................ 4
. INSPECTION OF ACTUATOR INPUT SIGNAL..... 8
H
INSTALLATION .................................................... 4
. INSPECTION OF CONTROL UNIT OUTPUT
INSPECTION AFTER INSTALLATION ................ 4 . SIGNAL ................................................................ 8
.
DUAL MODE MUFFLER ........................................... 5 . INSPECTION OF CONTROL UNIT INPUT SIG-
Removal and Installation ......................................... 5
. NAL ...................................................................... 9
. I
REMOVAL (CABLE) ............................................. 5. INSPECTION OF ECM OUTPUT SIGNAL ........... 9 .
INSTALLATION .................................................... 5
. INSPECTION OF HARNESS CONTINUITY ........ 9 .
REMOVAL (ACTUATOR) ..................................... 5 . SERVICE DATA AND SPECIFICATIONS (SDS) ..... 10 . J
INSTALLATION .................................................... 6
. Tightening Torque .................................................. 10.

Revision: 2004 April EX-1 2002 Q45
PREPARATION

PREPARATION PFP:00002

Special Service Tools EBS003GD

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
(Kent-Moore No.) Description
Tool name

KV10114400 Loosening or tightening heated oxygen
(J-38365) sensors
Heated oxygen sensor wrench a: 22 mm (0.87 in)

S-NT636

Commercial Service Tools EBS003GE

Tool number
(Kent-Moore No.) Description
Tool name

(J-43897-18)
Reconditioning the exhaust system threads
(J-43897-12)
before installing a new oxygen sensor (Use
Oxygen sensor thread cleaner
with anti-seize lubricant shown below.)
a: J-43897-18 (18 mm dia.) for zirconia
oxygen sensor
b: J-43897-12 (12 mm dia.) for titania
oxygen sensor
AEM488

Anti-seize lubricant (Permatex 133AR
or equivalent meeting MIL
specification MIL-A-907)
Lubricating oxygen sensor thread cleaning
tool when reconditioning exhaust system
threads

AEM489

Revision: 2004 April EX-2 2002 Q45
EXHAUST SYSTEM

EXHAUST SYSTEM PFP:20100
A
Checking Exhaust System EBS004VQ

Check exhaust pipes, muffler and mounting for improper attachment,
leaks, cracks, damage or deterioration. EX

SMA211A

E
Removal and Installation EBS001JQ

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 the engine stops.
G
q Be careful not to cut your hand on the insulator edge.

PBIC0171E

1. Main muffler 2. Actuator 3. Gasket
4. Ground cable 5. Cable 6. Mounting rubber
7. Exhaust front tube 8. Bracket 9. Heated oxygen sensor 2 (rear) (bank 2)

Revision: 2004 April EX-3 2002 Q45
EXHAUST SYSTEM

10. Heated oxygen sensor 2 (rear) (bank 1) 11. Ring gasket 12. Bracket
13. Bracket 14. Gasket 15. Center muffler

REMOVAL
1. Remove cable from exhaust control valve.
Refer to Dual mode muffler, EX-5, "Removal and Installation" .
2. Disconnect each joint and mounting.
INSTALLATION
q Install in the reverse order of removal.
CAUTION:
q Always replace exhaust gaskets with new ones when reassembling.
q Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
q Before installing a new oxygen sensor, clean exhaust system threads using oxygen sensor thread
cleaner tool, J-43897-18 or J-43897-12, and apply anti-seize lubricant.
q Do not over torque the oxygen sensor. Doing so may cause damage to the oxygen sensor, result-
ing in the MIL coming on.
q If the insulator is badly deformed, repair or replace it. If deposits such as mud pile up on the insu-
lator, remove them.
q When installing the insulator avoid large gaps or interference between the insulator and each
exhaust pipe.
q Remove deposits and left over gasket material from the sealing surface of each connection. Con-
nect 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 abnormal interference, and then tighten them to the specified torque.
q When installing each clamp, align the protrusion on the insulator with the clamp hole.
q When installing each mounting rubber, avoid twisting or abnormal extension in up/down and right/
left directions.
q Install mounting rubbers on rear main muffler as shown.

PBIC0172E

INSPECTION AFTER INSTALLATION
q With the engine running, check exhaust tube joints for gas leakage and unusual noises.
q Check to ensure that mounting brackets and mounting insulators are installed properly and free from
undue stress. Improper installation could result in excessive noise and vibration.

Revision: 2004 April EX-4 2002 Q45
DUAL MODE MUFFLER

DUAL MODE MUFFLER PFP:20130
A
Removal and Installation EBS001ZA

PBIC0173E
G

1. Bracket 2. Cover 3. Cable
4. Center muffler 5. Exhaust control valve (Do not disassemble.) 6. Actuator H
7. Muffler control unit

NOTE:
Exhaust control valve is provided in center muffler and not permitted to disassemble. I
REMOVAL (CABLE)
NOTE:
J
Removal and installation procedure is the same on both side of actuator and exhaust control valve.
1. Remove cable from actuator and exhaust control valve.
q Loosen lock nut A.
K
q Do not loosen positioning nuts B and C.

2. Remove middle clamp bolt and cable.
q Install in the reverse order of removal. L
q Install cable on cable bracket and then tighten lock nut A to
specified torque.
M

PBIC0174E

INSTALLATION
q To avoid twisting the cable when tightening the lock nut A, hold the positioning nut B or C with a wrench.
q If the positioning nuts B and C are loosened, place the nut B so that span D becomes 17.5 mm (0.689 in)
to 18.5 mm (0.728 in). Hold the nut B with a wrench and tighten the nut C to specified torque.
NOTE:
Additional adjustment is unnecessary.
REMOVAL (ACTUATOR)
1. Remove insulator on lower side of actuator.
2. Remove harness connector and cable from actuator.
Refer to EX-5, "REMOVAL (CABLE)" .
3. Remove actuator.

Revision: 2004 April EX-5 2002 Q45
DUAL MODE MUFFLER

INSTALLATION
q Install in the reverse order of removal.
REMOVAL (MUFFLER CONTROL UNIT)
1. Open trunk lid, and remove trunk side finisher (right).
2. Remove muffler control unit fixing bolt.
3. Remove harness connector and muffler control unit along with
bracket.
CAUTION:
Do not drop or damage muffler control unit when removing.

PBIC0175E

INSTALLATION
q Install in the reverse order of removal.

Revision: 2004 April EX-6 2002 Q45
DUAL MODE MUFFLER

Trouble Diagnoses EBS002O9

WIRING DIAGRAM A

TBWM0058E

PARTS LOCATION

PBIC0175E

Revision: 2004 April EX-7 2002 Q45
DUAL MODE MUFFLER

PBIC0177E

INSPECTION OF VALVE OPERATION
q Check operation of valve and actuator by revving engine.
When accelerator pedal position sensor opening is below half in no-load
condition:
Valve should open at engine revolution above approximate 4,800 rpm.
Valve should close at engine revolution below approximate 4,700 rpm.
When accelerator pedal position sensor opening is over half in loaded con-
dition:
Valve should open at engine revolution above approximate 2,600 rpm.
Valve should close at engine revolution below approximate 2,500 rpm. PBIZ0004J

INSPECTION OF ACTUATOR INPUT SIGNAL
q Check voltage between terminals 1 and 2 of actuator connector
and ground.
Condition Valve open Valve close
Battery voltage
Between terminal No.1 and ground 0-1V
equivalent
Battery voltage
Between terminal No.2 and ground 0-1V
equivalent

PBIC0178E

INSPECTION OF CONTROL UNIT OUTPUT SIGNAL
q Check voltage between terminals and ground.
Condition Valve open Valve close
Battery voltage
Between terminal No.4 and ground 0V
equivalent
Battery voltage
Between terminal No.5 and ground 0V
equivalent

PBIC0179E

Revision: 2004 April EX-8 2002 Q45
DUAL MODE MUFFLER

INSPECTION OF CONTROL UNIT INPUT SIGNAL
q Check voltage at idling engine. A

Between terminal No.1 and ground
Battery voltage
(Battery signal)
EX
Between terminal No.3 and ground
Approx. 4 - 6 V
(Rev. signal)
Between terminal No.2 and ground
(Earth signal)
0V C

Accelerator pedal position sensor
opening is over
Between terminal No.6 and ground D
half: More than approx. 2.4 V PBIC0180E
(Accelerator pedal position sensor
Accelerator pedal position sensor
opening signal)
opening is below half:
Approx. 0 - 2.4 V
E
INSPECTION OF ECM OUTPUT SIGNAL
q Check that tachometer operates normally.
q Check voltage between terminals and ground at idling engine. F

Between ECM terminal No.38 and
Approx. 4 - 6 V
ground
G
Accelerator pedal position sensor
opening is over half:
Between ECM terminal No.113 and More than approx. 2.4 V
ground Accelerator pedal position sensor H
opening is below half:
Approx. 0 - 2.4 V
PBIC0181E

I
INSPECTION OF HARNESS CONTINUITY
q Remove connectors of ECM, muffler control unit and actuator.
Check resistance between terminals.
J
Between actuator terminal No.1 and muffler control unit terminal
No.4:
Between actuator terminal No.2 and muffler control unit terminal
No.5: K
0
Between ECM terminal No.38 and muffler control unit terminal
No.3:
Between ECM terminal No.113 and muffler control unit terminal L
No.6:
PBIC0182E

Revision: 2004 April EX-9 2002 Q45
SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

Tightening Torque EBS001Z8

Unit: N

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