ENGINE

SECTION
EXHAUST SYSTEM
EX EX

E
CONTENTS
MR20DE ON-VEHICLE MAINTENANCE ..................... 9 F

PRECAUTION ............................................... 2 EXHAUST SYSTEM ........................................... 9

Inspection ................................................................. 9 G
PRECAUTIONS ................................................... 2
Removal and Installation ........................................... 2 ON-VEHICLE REPAIR ................................. 10
PREPARATION ............................................ 3 EXHAUST SYSTEM .......................................... 10 H
Exploded View .........................................................10
PREPARATION ................................................... 3 Removal and Installation .........................................10
Special Service Tools ................................................ 3 Inspection ................................................................11 I
Commercial Service Tools ........................................ 3 M9R
ON-VEHICLE MAINTENANCE ..................... 4 PRECAUTION .............................................. 12
J
EXHAUST SYSTEM ............................................ 4 PRECAUTIONS ................................................. 12
Inspection .................................................................. 4 Removal and Installation .........................................12
ON-VEHICLE REPAIR .................................. 5 K
ON-VEHICLE MAINTENANCE .................... 13
EXHAUST SYSTEM ............................................ 5 EXHAUST SYSTEM .......................................... 13
Exploded View .......................................................... 5 Inspection ................................................................13 L
Removal and Installation ........................................... 5
Inspection .................................................................. 7 ON-VEHICLE REPAIR ................................. 14
QR25DE M
EXHAUST SYSTEM .......................................... 14
PRECAUTION ............................................... 8 Exploded View .........................................................14
Removal and Installation .........................................14
PRECAUTIONS ................................................... 8 Inspection ................................................................15 N
Removal and Installation ........................................... 8

EX-1 GETtheMANUALS.org
 PRECAUTIONS
< PRECAUTION > [MR20DE]

PRECAUTION
PRECAUTIONS
Removal and Installation INFOID:0000000001160886

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.

EX-2 GETtheMANUALS.org
 PREPARATION
< PREPARATION > [MR20DE]

PREPARATION A
PREPARATION
Special Service Tools INFOID:0000000001160887
EX

Tool number
Description C
Tool name
KV10114400 Loosening or tightening heated oxygen sen-
Heated oxygen sensor wrench sor 2
For 22 mm (0.87 in) width hexagon nut D

E
S-NT636

Commercial Service Tools INFOID:0000000001160888 F

Tool name Description G

Heated oxygen sensor thread cleaner Reconditioning the exhaust system threads
before installing a new heated oxygen sensor
(Use with anti-seize lubricant shown below.) H
a: 18 mm (0.71 in) dia. for zirconia heated
oxygen sensor
b: 12 mm (0.47 in) dia. for titania heated ox-
ygen sensor I

AEM488

Anti-seize lubricant (Permatex 133AR Lubricating heated oxygen sensor thread J

or equivalent meeting MIL specifica- cleaner when reconditioning exhaust system
tion MIL-A-907) threads

AEM489
L

EX-3 GETtheMANUALS.org
 EXHAUST SYSTEM
< ON-VEHICLE MAINTENANCE > [MR20DE]

ON-VEHICLE MAINTENANCE
EXHAUST SYSTEM
Inspection INFOID:0000000001160889

Check exhaust pipes, muffler and mounting for improper attachment,

leakage, cracks, damage or deterioration.
• If anything is found, repair or replace damaged parts.

SMA211A

EX-4 GETtheMANUALS.org
 EXHAUST SYSTEM
< ON-VEHICLE REPAIR > [MR20DE]

ON-VEHICLE REPAIR A
EXHAUST SYSTEM
Exploded View INFOID:0000000001160890
EX

JPBIA0560GB K

1. Mounting rubber 2. Mounting rubber 3. Mounting rubber

4. Main muffler 5. Spring 6. Insulator L
7. Seal bearing 8. Exhaust front tube 9. Stud bolt
10. Heated oxygen sensor 2
A. Insulator (4WD models) M
Refer to GI-4, "Components" for symbols in the figure.

Removal and Installation INFOID:0000000001160891

N

REMOVAL
• Disconnect each joint and mounting.
O
• Remove heated oxygen sensor 2 with following procedure.

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 EXHAUST SYSTEM
< ON-VEHICLE REPAIR > [MR20DE]
- Using heated oxygen sensor wrench [SST: KV10114400] (A),
removal heated oxygen sensor 2 (1).
CAUTION:
Be careful not to damage heated oxygen sensor 2.

JPBIA0460ZZ

INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
• Always replace seal bearings 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 and apply anti-seize lubricant (commercial service tool).
• Never over torque heated oxygen sensor 2. Doing so may cause damage to the heated oxygen sen-
sor 2, resulting in the “MI” 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 gas
leakage.
• If it is difficult to install mounting rubber, use mild detergent for smooth installation.
• Temporarily tighten mounting nuts and bolts. 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.
Exhaust Manifold to Exhaust Front Tube
1. Securely insert seal bearing (2) into exhaust manifold (1) side in
the direction shown in figure.

3 : Spring
4 : Mounting nut
5 : Exhaust front tube
CAUTION:
Be careful not to damage seal bearing surface when install-
ing.
2. With spring, tighten mounting nut. JPBIA0978ZZ
• Be careful that mounting nut does not interfere with flanged
area ( ), and tighten it.
CAUTION:
• Fasten stud bolts to the flange of exhaust manifold side to the specified torque before fastening
mounting nuts.
• Ensure springs are seated correctly on the flange and not sitting on (A).
Exhaust Front Tube to Main Muffler

EX-6 GETtheMANUALS.org
 EXHAUST SYSTEM
< ON-VEHICLE REPAIR > [MR20DE]
1. Securely insert seal bearing (2) into exhaust front tube (1) side
in the direction shown in figure. A

3 : Spring
4 : Mounting bolt EX
5 : Main muffler
CAUTION:
Be careful not to damage seal bearing surface when install- C
ing.
2. With spring, tighten mounting bolt. PBIC3798E
• Be careful that mounting bolt does not interfere with flanged D
area ( ), and tighten it.
Inspection INFOID:0000000001160892

E
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. F
• 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.
G

EX-7 GETtheMANUALS.org
 PRECAUTIONS
< PRECAUTION > [QR25DE]

PRECAUTION
PRECAUTIONS
Removal and Installation INFOID:0000000001160879

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.

EX-8 GETtheMANUALS.org
 EXHAUST SYSTEM
< ON-VEHICLE MAINTENANCE > [QR25DE]

ON-VEHICLE MAINTENANCE A
EXHAUST SYSTEM
Inspection INFOID:0000000001160882
EX
Check exhaust pipes, muffler and mounting for improper attachment,
leakage, cracks, damage or deterioration.
• If anything is found, repair or replace damaged parts. C

SMA211A

EX-9 GETtheMANUALS.org
 EXHAUST SYSTEM
< ON-VEHICLE REPAIR > [QR25DE]

ON-VEHICLE REPAIR
EXHAUST SYSTEM
Exploded View INFOID:0000000001160883

JPBIA0559GB

1. Mounting rubber 2. Mounting rubber 3. Mounting rubber

4. Main muffler 5. Insulator 6. Gasket
7. Exhaust center tube 8. Mounting rubber 9. Exhaust front tube
10. Gasket
Refer to GI-4, "Components" for symbols in the figure.

Removal and Installation INFOID:0000000001160884

REMOVAL
• Disconnect each joint and mounting.
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
• Always replace exhaust gasket with new ones when reassembling.
• 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 gas
leakage.
• If it is difficult to install mounting rubber, use mild detergent for smooth installation.

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 EXHAUST SYSTEM
< ON-VEHICLE REPAIR > [QR25DE]
• When installing each mounting rubber, avoid twisting or unusual extension in up/down and right/left
directions. A
• Temporarily tighten mounting nuts and bolts. Check each part for unusual interference, and then
tighten them to the specified torque.
Inspection INFOID:0000000001160885 EX

INSPECTION AFTER INSTALLATION

• Check clearance between tail tube and rear bumper is even. C
• 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. D

EX-11 GETtheMANUALS.org
 PRECAUTIONS
< PRECAUTION > [M9R]

PRECAUTION
PRECAUTIONS
Removal and Installation INFOID:0000000001160893

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.

EX-12 GETtheMANUALS.org
 EXHAUST SYSTEM
< ON-VEHICLE MAINTENANCE > [M9R]

ON-VEHICLE MAINTENANCE A
EXHAUST SYSTEM
Inspection INFOID:0000000001160894
EX
Check exhaust pipes, muffler and mounting for improper attachment,
leaks, cracks, damage or deterioration.
• If anything is found, repair or replace damaged parts. C

SMA211A

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 EXHAUST SYSTEM
< ON-VEHICLE REPAIR > [M9R]

ON-VEHICLE REPAIR
EXHAUST SYSTEM
Exploded View INFOID:0000000001160895

JPBIA0755GB

1. Gasket 2. Exhaust front tube 3. Exhaust gas temperature sensor 2

4. Exhaust gas temperature sensor 3 5. Gasket 6. Insulator
Differential exhaust pressure sensor Differential exhaust pressure sensor
7. 8. Mounting rubber 9.
tube tube
Differential exhaust pressure sensor Differential exhaust pressure sensor
10. Differential exhaust pressure sensor 11. 12.
bracket hose
13. Insulator 14. Mounting rubber 15. Main muffler
16. Mounting rubber 17. Mounting rubber 18. Mounting rubber
A. Insulator (4WD models)
Refer to GI-4, "Components" for symbols in the figure.

Removal and Installation INFOID:0000000001160896

REMOVAL
1. Remove main muffler.

EX-14 GETtheMANUALS.org
 EXHAUST SYSTEM
< ON-VEHICLE REPAIR > [M9R]
2. Disconnect exhaust gas temperature sensor harness connectors.
3. Disconnect differential exhaust pressure sensor hoses from exhaust front tube. A
4. Remove exhaust front tube.
5. Remove differential exhaust pressure sensor tubes and differential exhaust pressure sensor.
CAUTION: EX
Never deform differential exhaust pressure sensor tubes.
6. Remove exhaust gas temperature sensors, if necessary.
CAUTION: C
Never remove exhaust gas temperature sensors except for replacing with new parts.
INSTALLATION
Note the following, and install in the reverse order of removal. D

Exhaust Gas Temperature Sensor

• Install exhaust gas temperature sensor in the original position.
CAUTION: E
• Before installing a new exhaust gas temperature sensor, clean front tube thread.
• Be careful not to impact or damage exhaust gas temperature sensors.
• When installing, never use such tools as an air impact wrench. F
Differential Exhaust Pressure Sensor
CAUTION:
• Never deform differential exhaust pressure sensor tubes. G
• Clamp shall not run aground on bulge.
Exhaust Front Tube and Main Muffler
CAUTION: H
• Always replace exhaust gaskets with new ones when reassembling.
• If the insulator is badly deformed, repair or replace it. If deposits such as mud pile up on the insula-
tor, remove them. I
• When installing the insulator avoid large gaps or interference between the insulator and each
exhaust pipe.
• Remove deposits from the sealing surface of each connection. Connect them securely to avoid gas
leakage. J
• If it is difficult to install mounting rubber, use mild detergent for smooth installation.
• When installing each mounting rubber, avoid twisting or unusual extension in up/down and right/left
directions. K
• Temporarily tighten mounting nuts. Check each part for unusual interference, and then tighten them
to the specified torque.
Inspection INFOID:0000000001160897 L

INSPECTION AFTER INSTALLATION

• With the engine running, check exhaust tube joints for gas leakage and unusual noises. M
• 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.
N

EX-15 GETtheMANUALS.org