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EXHAUST SYSTEM

B ENGINE

EX
SECTION
EXHAUST SYSTEM C

E
CONTENTS
PREPARATION .......................................................... 2
. INSTALLATION .................................................... 6
. F
Special Service Tools .............................................. 2
. Trouble Diagnoses .................................................. 7
.
Commercial Service Tools ....................................... 2
. WIRING DIAGRAM .............................................. 7.
EXHAUST SYSTEM .................................................. 3
. PARTS LOCATION ............................................... 8
. G
Checking Exhaust System ...................................... 3 . INSPECTION OF VALVE OPERATION ............... 8 .
Removal and Installation ......................................... 3
. INSPECTION OF DUAL MODE MUFFLER
REMOVAL ............................................................ 4
. ACTUATOR INPUT SIGNAL ................................ 8 .
H
INSTALLATION .................................................... 4
. INSPECTION OF DUAL MODE MUFFLER CON-
INSPECTION AFTER INSTALLATION ................ 4 . TROL UNIT OUTPUT SIGNAL ............................ 9 .
DUAL MODE MUFFLER ........................................... 5 . INSPECTION OF DUAL MODE MUFFLER CON-
Removal and Installation ......................................... 5
. TROL UNIT INPUT SIGNAL ................................ 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
.
REMOVAL (MUFFLER CONTROL UNIT) ........... 6 .
K

Revision; 2004 April EX-1 2003 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

(Kent-Moore No.)
Description
Tool name

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

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

AEM489

Power tool Loosening bolts and nuts

PBIC0190E

Revision; 2004 April EX-2 2003 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.

PBIC0956E

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 (bank 2)

Revision; 2004 April EX-3 2003 Q45
EXHAUST SYSTEM

10. Heated oxygen sensor 2 (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
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 heated oxygen sensor, clean exhaust system threads using heated oxygen
sensor thread cleaner tool, J-43897-18 or J-43897-12, and apply anti-seize lubricant.
q Do not over torque the heated oxygen sensor. Doing so may cause damage to the heated oxygen
sensor, resulting 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 2003 Q45
DUAL MODE MUFFLER

DUAL MODE MUFFLER PFP:20130
A
Removal and Installation EBS00LS4

G
SBIA0404E

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

NOTE: I
Exhaust control valve is provided in center muffler and not permitted to disassemble.
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.
L

PBIC0174E

INSTALLATION
q Install in the reverse order of removal.
q Install cable on cable bracket and then tighten lock nut A to specified torque.
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. Disconnect harness connector and cable from actuator.
Refer to EX-5, "REMOVAL (CABLE)" .

Revision; 2004 April EX-5 2003 Q45
DUAL MODE MUFFLER

3. Remove actuator.
INSTALLATION
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. Disconnect harness connector and remove muffler control unit
along with bracket.
CAUTION:
Do not drop or damage muffler control unit when removing.

PBIC0175E

INSTALLATION
Install in the reverse order of removal.

Revision; 2004 April EX-6 2003 Q45
DUAL MODE MUFFLER

Trouble Diagnoses EBS00LS5

WIRING DIAGRAM A

TBWM0176E

Revision; 2004 April EX-7 2003 Q45
DUAL MODE MUFFLER

PARTS LOCATION

PBIC0175E

PBIC0177E

INSPECTION OF VALVE OPERATION
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 4,830 rpm.
Valve should close at engine revolution below approximate 4,730 rpm.
When accelerator pedal position sensor opening is over half in loaded condition:
Valve should open at engine revolution above approximate 475 rpm.
Valve should close at engine revolution below approximate 375 rpm.

PBIZ0004J

INSPECTION OF DUAL MODE MUFFLER ACTUATOR INPUT SIGNAL
Check voltage between terminals 1 and 2 of dual mode muffler actu-
ator harness connector and ground.
Terminals
Input
(+) (-) signal
Condition Voltage V
(Exhaust
Terminal
control valve)
(Wire color)
Battery voltage
1 (G/Y) Open 0-1
(11 - 14)
GND ING ON
Battery voltage
2 (G/R) Close 0-1
(11 - 14) PBIC0178E

Revision; 2004 April EX-8 2003 Q45
DUAL MODE MUFFLER

INSPECTION OF DUAL MODE MUFFLER CONTROL UNIT OUTPUT SIGNAL
Check voltage between terminals 4 and 5 of dual mode muffler con- A
trol unit harness connector and ground.
Terminals
Input
EX
(+) (-) signal
Condition Voltage V
(Exhaust
Terminal
control valve)
(Wire color)
C
Battery voltage
4 (G/Y) Open 0-1
(11 - 14)
GND ING ON
Battery voltage
5 (G/R) Close 0-1
(11 - 14) PBIC0179E
D

INSPECTION OF DUAL MODE MUFFLER CONTROL UNIT INPUT SIGNAL
Check voltage between terminals 1, 2, 3 and 6 of dual mode muffler E
control unit harness connector and ground.
Terminals
(+) (-) Input signal Condition Voltage V F
Terminal (Wire color)

Battery voltage
G
1 (W/G) Battery
ING ON (11 - 14)

3 (L) Revolution Idling Approx. 4 - 6 PBIC0180E H
GND
2 (B) Earth IGN OFF 0

Accelerator More than
Over half I
6 (R/Y) pedal position ING ON approx. 2.4
sensor opening Below half Approx. 0 - 2.4

INSPECTION OF ECM OUTPUT SIGNAL J
q Check that tachometer operates normally.
q Check voltage between ECM terminals 38, 113 and ground at
idling engine. K
Terminals
(+) (-) Output signal Condition Voltage V
L
Terminal (Wire color)
38 (W/G) Revolution Idling Approx. 4 - 6

Accelerator More than M
GND Over half
113 (R/Y) pedal position IGN ON approx. 2.4 PBIC0181E

sensor opening Below half Approx. 0 - 2.4

INSPECTION OF HARNESS CONTINUITY
Disconnect connectors of ECM, dual mode muffler control unit and
actuator. Check resistance between terminals.
Terminals (Wire color) Resistance
Actuator terminal 1 (G/Y) and muffler control unit terminal 4 (G/Y)
Actuator terminal 2 (G/R) and muffler control unit terminal 5 (G/R)
0
ECM terminal 38 (W/G) and muffler control unit terminal 3 (L)
ECM terminal 113 (R/Y) and muffler control unit terminal 6 (R/Y)

PBIC0182E

Revision; 2004 April EX-9 2003 Q45
SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

Tightening Torque EBS001Z8

Unit: N

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