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EXHAUST SYSTEM

B ENGINE

EX
SECTION
EXHAUST SYSTEM C

E
CONTENTS
PREPARATION .......................................................... 2
. INSTALLATION (CR ENGINE) ............................. 5 . F
Special Service Tool ................................................ 2
. INSTALLATION (K9K ENGINE) ........................... 6 .
EXHAUST SYSTEM .................................................. 3
. Inspection After Installation ..................................... 6
.
Checking Exhaust System ...................................... 3 . SERVICE DATA AND SPECIFICATIONS (SDS) ....... 7 . G
Removal and Installation ......................................... 3
. Tightening Torque .................................................... 7
.
CR ENGINE ......................................................... 3
. CR ENGINE ......................................................... 7
.
K9K ENGINE ........................................................ 4
. K9K ENGINE ........................................................ 7
.
H
REMOVAL ............................................................ 4
.

EX-1
PREPARATION

PREPARATION PFP:00002

Special Service Tool EBS00OJC

Tool number
Description
Tool name

KV10117200 Loosening or tightening heated oxygen
Heated oxygen sensor wrench sensors
a: 22 mm (0.87 in)

S-NT636

EX-2
EXHAUST SYSTEM

EXHAUST SYSTEM PFP:20100
A
Checking Exhaust System EBS00OJQ

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

SMA211A

E
Removal and Installation EBS00OJD

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 is still hot
just after the engine stops.
G
q Be careful not to cut your hand on the insulator edge.
CR ENGINE
H

PBIC1510E

1. Main muffler 2. Mounting rubber 3. Ring gasket
4. Mounting rubber 5. Center muffler 6. Ground cable
7. Mounting bracket 8. Heated oxygen sensor 2 9. Seal bearing
10. Spring 11. Exhaust front tube 12. Seal bearing
13. Spring

EX-3
EXHAUST SYSTEM

K9K ENGINE

MBIB1055E

1. Main muffler 2. Mounting rubber 3. Ring gasket
4. Mounting rubber 5. Exhaust center tube 6. Exhaust front tube
7. Gasket

REMOVAL
q Disconnect each joint and mounting.
Heated Oxygen Sensor 2 (CR Engine)
q When removing heated oxygen sensor 2 on vehicle, perform following procedure.
1. Disconnect harness connector.
2. Use a heated oxygen sensor wrench (special service tool) for
removal of heated oxygen sensor 2.
CAUTION:
q Do not apply impact while handling.

PBIC1511E

EX-4
EXHAUST SYSTEM

Exhaust Front Tube (CR Engine)
1. Disconnect center muffler connecting points. A
2. Remove the ground cable on vehicle.
3. Remove mount bracket mounting nuts on suspension member.
EX
4. Disconnect three way catalyst connecting points to remove
exhaust front tube.

PBIC1512E
D

INSTALLATION (CR ENGINE)
Install in the reverse order of removal paying attention to the following. E
q Remove all deposits, such as old gasket, from the sealing surfaces of each connection. Connect firmly
without any leaks.
q When installing exhaust pipe assembly, temporarily tighten nuts on the exhaust manifold side mounting F
bolts and vehicle side mounting nuts. After making sure there is no unusual tension on each part, tighten
nuts and bolts to the specified torque.
q Be careful not to twist or apply excess tension in any direction when installing mounting rubbers.
G
q Because thickness is different between center muffler rear side mounting rubber and main muffler side
mounting rubbers, install thick mount rubber at main muffler side.
q Install seal bearing unit in the following procedures. H
q When installing heated oxygen sensor 2, use heated oxygen sensor wrench (special service tool:
KV10117200).
CAUTION: I
q Do not apply impact while handing.

q Do not use heated oxygen sensor 2 after being dropped on a solid concrete floor, from a height
of 0.5 m (1.6 ft) or higher. Replace it with a new one.
J
q Do not tighten heated oxygen sensor 2 to a torque larger than specified. Excess tightening may
result in damage of heated oxygen sensor 2, causing MI to turn ON.
q when using heated oxygen sensor wrench (special service tool: KV10117200), tighten to the
K
middle of specified torque because length of tool may induce slight indication increase. Do not
tighten to the maximum specified torque.
Three Way Catalyst to Exhaust Front Tube L
1. Securely insert seal bearing into three way catalyst side in the
direction shown in figure.
CAUTION: M
Be careful not to damage seal bearing surface when install-
ing.
2. With spring large diameter side facing to exhaust front tube
flange, tighten mounting bolt.
q Be careful that mounting bolt does not interfere with flanged
area, and tighten it.
PBIC1513E

EX-5
EXHAUST SYSTEM

Exhaust Front Tube to Center Muffler
1. Securely insert seal bearing into exhaust front tube side in the
direction shown in figure.
CAUTION:
Be careful not to damage seal bearing surface when install-
ing.
2. With spring large diameter side facing to center muffler flange,
tighten mounting bolt.
q Be careful that mounting bolt does not interfere with flanged
area, and tighten it.
PBIC1514E

INSTALLATION (K9K ENGINE)
q Install in the reverse order of removal.
CAUTION:
q Always replace exhaust gaskets with new ones when reassembling.
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 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 EBS01C86

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.

EX-6
SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030
A
Tightening Torque EBS00OJE

CR ENGINE
Unit: N

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