Config(EX) EX
User Manual: EX
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EX-1
ENGINE
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SECTION EX A
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CONTENTS
EXHAUST SYSTEM
PRECAUTION ............................................... 2
PRECAUTIONS ................................................... 2
Removal and Installation ...........................................2
PREPARATION ............................................ 3
PREPARATION ................................................... 3
Special Service Tool .................................................3
Commercial Service Tool ..........................................3
ON-VEHICLE MAINTENANCE ..................... 4
EXHAUST SYSTEM ........................................... 4
Inspection ................................................................. 4
ON-VEHICLE REPAIR .................................. 5
EXHAUST SYSTEM ........................................... 5
Exploded View .......................................................... 5
Removal and Installation .......................................... 6
Inspection ................................................................. 6
Revision: 2007 November 2008 EX35
EX-2
< PRECAUTION >
PRECAUTIONS
PRECAUTION
PRECAUTIONS
Removal and Installation INFOID:0000000003134597
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 heat insulator edge.
Revision: 2007 November 2008 EX35
PREPARATION
EX-3
< PREPARATION >
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PREPARATION
PREPARATION
Special Service Tool INFOID:0000000003134598
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Commercial Service Tool INFOID:0000000003134599
Tool number
(Kent-Moore No.)
Tool name
Description
KV10114400
(J-38365)
Heated oxygen sensor wrench
Loosening or tightening heated oxygen sen-
sor 2
For 22 mm (0.87 in) (a) width hexagon nut
S-NT636
(Kent-Moore No.)
Tool name Description
A: (J-43897-18)
B: (J-43897-12)
Heated oxygen sensor thread cleaner
Reconditioning the exhaust system threads
before installing a new heated oxygen sensor
(Use with anti-seize lubricant shown below.)
A: J-43897-18 [18 mm (0.71 in) dia.] for zir-
conia heated oxygen sensor
B: J-43897-12 [12 mm (0.47 in) dia.] for tita-
nia heated oxygen sensor
C: Mating surface shave cylinder
D: Flutes
(—)
Anti-seize lubricant (Permatex 133AR
or equivalent meeting MIL specifica-
tion MIL-A-907)
Lubricating heated oxygen sensor thread
cleaner when reconditioning exhaust system
threads
(—)
Power tool
Loosening bolts and nuts
JPBIA0238ZZ
AEM489
PBIC0190E
Revision: 2007 November 2008 EX35
EX-4
< ON-VEHICLE MAINTENANCE >
EXHAUST SYSTEM
ON-VEHICLE MAINTENANCE
EXHAUST SYSTEM
Inspection INFOID:0000000003134600
Check exhaust pipes, muffler and mounting for improper attachment,
leakage, cracks, damage or deterioration.
• If anything is found, repair or replace damaged parts.
SMA211A
Revision: 2007 November 2008 EX35
EXHAUST SYSTEM
EX-5
< ON-VEHICLE REPAIR >
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ON-VEHICLE REPAIR
EXHAUST SYSTEM
Exploded View INFOID:0000000003486751
1. Mounting bracket 2. Mounting rubber 3. Main muffler
4. Dynamic damper 5. Mounting rubber 6. Gasket
7. Mounting rubber 8. Mounting bracket 9. Center muffler
10. Gasket 11. Three way catalyst (bank 1) 12. Heated oxygen sensor 2 (bank 1)
13. Collar 14. Grommet 15. Exhaust mounting bracket
16. Grommet 17. Heated oxygen sensor 2 (bank 2) 18. Three way catalyst (bank 2)
19. Gasket 20. Dynamic damper 21. Exhaust front tube
22. Gasket
Refer to GI-4, "Components" for symbols in the figure.
JPBIA1839GB
Revision: 2007 November 2008 EX35
EX-6
< ON-VEHICLE REPAIR >
EXHAUST SYSTEM
Removal and Installation INFOID:0000000003134602
REMOVAL
• Disconnect each joint and mounting using power tool.
• Remove heated oxygen sensor 2 as follows:
- Using heated oxygen sensor wrench [SST: KV10114400 (J-
38365)] (C), removal heated oxygen sensor 2.
CAUTION:
Be careful not to damage heated oxygen sensor 2.
INSTALLATION
Note the following, and install in the reverse order of removal.
• Check for deformation of the grommets (14 and 16 of Components).
• Insert the collar (13 of Components) vertically.
• Temporarily tighten bolts and nuts when installing exhaust pipe assembly. Tighten them to the specified
torque when connecting the vehicle rear to the vehicle front.
CAUTION:
• Always replace exhaust tube gaskets with new ones when reassembling.
• Discard any heated oxygen sensor 2 which has been dropped onto a hard surface such as a con-
crete floor. Use a new one.
• Before installing a new heated oxygen sensor 2, clean exhaust system threads using the heated oxy-
gen sensor thread cleaner [commercial service tool: J-43897-18 or J-43897-12], and apply the anti-
seize lubricant (commercial service tool).
• Never over torque heated oxygen sensor 2. Doing so may cause damage to heated oxygen sensor 2,
resulting in the “MIL” coming on.
• If heat insulator is badly deformed, repair or replace it. If deposits such as mud pile up on the heat
insulator, remove them.
• When installing heat insulator avoid large gaps or interference between heat insulator and each
exhaust pipe.
• Remove deposits from the sealing surface of each connection. Connect them securely to avoid
gases leakage.
• Temporarily tighten mounting nuts on the exhaust manifold side and mounting bolts on the vehicle
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.
Inspection INFOID:0000000003134603
INSPECTION AFTER INSTALLATION
• Check clearance between tail tube and rear bumper is even.
• With 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.
A: Bank 2
B: Bank 1
: Vehicle front
JPBIA0389ZZ
Revision: 2007 November 2008 EX35
