EXHAUST SYSTEM

B ENGINE

EX
SECTION
EXHAUST SYSTEM C

E
CONTENTS
EXHAUST SYSTEM ................................................... 2 SERVICE DATA AND SPECIFICATIONS (SDS) ........ 5 F
Checking Exhaust System ....................................... 2 Tightening Torque ..................................................... 5
Removal and Installation .......................................... 2 QR20DE AND QR25DE ........................................ 5
QR20DE AND QR25DE ........................................ 2 YD22DDTI ............................................................. 5 G
YD22DDTI ............................................................. 3
REMOVAL ............................................................. 3
INSTALLATION ..................................................... 3
H
INSPECTION AFTER INSTALLATION ................. 4

EX-1
 EXHAUST SYSTEM

EXHAUST SYSTEM PFP:20100

Checking Exhaust System EBS00AZ6

Check exhaust pipes, muffler and mounting for improper attachment,

leaks, cracks, damage or deterioration.
● If anything is found, repair or replace damaged parts.

SMA211A

Removal and Installation EBS003DN

CAUTION:
● Be sure to use genuine exhaust system parts or equivalents which are specially designed for heat
resistance, corrosion resistance and shape.
● Perform the operation with the exhaust system fully cooled down because the system will be hot
just after engine stops.
● Be careful not to cut your hand on the insulator edge.
QR20DE AND QR25DE

SBIA0434E

1. Main muffler 2. Mounting rubber 3. Spring

4. Gasket 5. Three way catalyst 6. Exhaust front tube
7. Seal bearing 8. Mounting rubber bracket 9. Mounting bracket
10. Exhaust center tube

EX-2
 EXHAUST SYSTEM

YD22DDTI
A

EX

PBIC2440E
I
1. Main muffler 2. Mounting rubber 3. Spring
4. Gasket 5. Exhaust tube 6. Exhaust front tube
7. Exhaust bracket 8. Mounting rubber bracket 9. Mounting bracket J
10. Exhaust center tube 11. Gasket 12. Seal bearing

REMOVAL K
Separate each connection as necessity.
INSTALLATION
L
Note the following, and install in the reverse order of removal.
CAUTION:
● Always replace exhaust gaskets and seal bearings with new ones when reassembling.
M
● If insulator is badly deformed, repair or replace it. If deposits such as mud pile up on insulator,
remove them.
● When installing insulator avoid large gaps or interference between insulator and each exhaust
pipe.
● Remove deposits from the sealing surface of each connection. Connect them securely to avoid
gas leakage.
● 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.
● When installing each mounting rubber, avoid twisting or unusual extension in up/down and right/
left directions.
● Install seal bearings at exhaust front tube and main muffler as follows.
CAUTION:
Do not mix the bolt and spring for seal bearing as the dimension is different for each seal bearing.

EX-3
 EXHAUST SYSTEM

Exhaust Front Tube Side (QR20DE and QR25DE)

Insert seal bearing in the direction shown in the figure.
CAUTION:
Tighten mounting bolt without causing interference with
exhaust front tube flange.

PBIC2274E

Main Muffler Side (QR20DE, QR25DE and YD22DDTi)

Insert seal bearing in the direction shown in the figure.
CAUTION:
Tighten mounting bolt without causing interference with main
muffler flange.

PBIC2275E

INSPECTION AFTER INSTALLATION

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

EX-4
 SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

A
Tightening Torque EBS00KP4

QR20DE AND QR25DE

Unit: N·m (kg-m, ft-lb)
EX
Exhaust system connections
Exhaust manifold three way catalyst assembly to exhaust front
43.1 - 54.9 (4.4 - 5.5, 32 - 40)
tube
C
Exhaust front tube to three way catalyst 51.0 - 64.7 (5.2 - 6.5, 38 - 47)
Three way catalyst to exhaust center tube 51.0 - 64.7 (5.2 - 6.5, 38 - 47)
Exhaust center tube to main muffler 43.1 - 54.9 (4.4 - 5.5, 32 - 40) D
Mounting bolts and nuts M8 12.7 - 15.7 (1.3 - 1.6, 10 - 11)

YD22DDTI E
Unit: N·m (kg-m, ft-lb)
Exhaust system connections
Catalyst rear diffuser to exhaust front tube 59.8 - 69.6 (6.1 - 7.0, 45 - 51) F
Exhaust front tube to exhaust tube 51.0 - 64.7 (5.2 - 6.5, 38 - 47)
Exhaust tube to exhaust center tube 51.0 - 64.7 (5.2 - 6.5, 38 - 47)
Exhaust center tube to main muffler 43.1 - 54.9 (4.4 - 5.5, 32 - 40)
G
Mounting bolts and nuts M8 12.7 - 15.7 (1.3 - 1.6, 10 - 11)

EX-5
SERVICE DATA AND SPECIFICATIONS (SDS)

EX-6