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EXHAUST SYSTEM

B ENGINE

SECTION
EXHAUST SYSTEM
EX EX

E
CONTENTS
APPLICATION NOTICE ............................................. 2
. K9K ENGINE (EURO 4 56KW/63KW MODELS).... 8 . F
How to Check Vehicle Type .................................... 2. REMOVAL ............................................................ 8
.
PREPARATION .......................................................... 3
. INSTALLATION (CR, HR ENGINE) ...................... 9 .
Special Service Tool ................................................ 3
. INSTALLATION (K9K ENGINE) ......................... 10 . G
EXHAUST SYSTEM .................................................. 4
. Inspection After Installation ................................... 10
.
Checking Exhaust System ...................................... 4. SERVICE DATA AND SPECIFICATIONS (SDS) ..... 11 .
Removal and Installation ......................................... 4
. Tightening Torque .................................................. 11
.
H
CR ENGINE ......................................................... 4
. CR ENGINE ....................................................... 11
.
HR ENGINE (HATCHBACK MODELS) ................ 5 . HR ENGINE ....................................................... 11
.
HR ENGINE (C+C MODELS) .............................. 6 . K9K ENGINE ...................................................... 11
.
K9K ENGINE (EURO 3 48KW/60KW MODELS).... 7 . I

EX-1
APPLICATION NOTICE

APPLICATION NOTICE PFP:00000

How to Check Vehicle Type EBS01LRJ

Confirm K9K engine type with Model written on identification plate (refer to GI-44, "IDENTIFICATION INFOR-
MATION" ),then refer to service information in EM section.
Vehicle type Engine type
xTKxxxxK12Vxx Euro3 48kW
xTKxxxxK12Yxx Euro3 60kW
xTKxxxxK12Txx Euro4 50kW
xTKxxxxK12Uxx Euro4 63kW

EX-2
PREPARATION

PREPARATION PFP:00002
A
Special Service Tool EBS00OJC

Tool number
Description
Tool name EX
KV10117200 Loosening or tightening heated oxygen
Heated oxygen sensor wrench sensors
a: 22 mm (0.87 in) C

D
S-NT636

EX-3
EXHAUST SYSTEM

EXHAUST SYSTEM PFP:20100

Checking Exhaust System EBS00OJQ

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

SMA211A

Removal and Installation EBS00OJD

CAUTION:
q Be sure to use genuine exhaust system parts or equivalents which are specially designed for heat
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.
q Be careful not to cut your hand on the insulator edge.
CR ENGINE

MBIB1268E

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-4
EXHAUST SYSTEM

HR ENGINE (HATCHBACK MODELS)
A

J
MBIB1430E

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

EX-5
EXHAUST SYSTEM

HR ENGINE (C+C MODELS)

MBIB1431E

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

EX-6
EXHAUST SYSTEM

K9K ENGINE (EURO 3 48KW/60KW MODELS)
A

MBIB1432E I
1. Main muffler 2. Mounting rubber 3. Ring gasket
4. Mounting rubber 5. Exhaust center tube 6. Exhaust front tube
J
7. Gasket

EX-7
EXHAUST SYSTEM

K9K ENGINE (EURO 4 56KW/63KW MODELS)

MBIB1425E

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, HR 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-8
EXHAUST SYSTEM

Exhaust Front Tube (CR, HR 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, HR 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-9
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-10
SERVICE DATA AND SPECIFICATIONS (SDS)

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

CR ENGINE
Unit: N

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