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.

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 the 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

PBIC1242E I
1. Main muffler 2. Mounting rubber 3. Spring
4. Ring gasket 5. Exhaust tube 6. Exhaust front tube
J
7. Exhaust bracket 8. Mounting rubber bracket 9. Mounting bracket
10. Exhaust center muffler 11. Gasket 12. Seal bearing

REMOVAL K
Separate each connection as necessity.
INSTALLATION
L
● Install in the reverse order of removal paying attention to the following.
CAUTION:
● Always replace exhaust gaskets with new ones when reassembling.
M
● If the insulator is badly deformed, repair or replace it. If deposits such as mud pile up on the
insulator, remove them.
● 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.
● 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.
● Install the seal bearings at front exhaust 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

Front Exhaust Side (QR20DE and QR25DE)

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

PBIC1243E

Main Muffler Side (QR20DE, QR25DE and YD22DDTi)

1. Insert the seal bearing in the direction shown in the figure.
2. Tighten the mounting bolt with the big end of the spring facing
the flange.
CAUTION:
Tighten the mounting bolt without causing interference with
the flange.

SBIA0147E

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 insulators 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 to exhaust front tube 43.1 - 54.9 (4.4 - 5.5, 32 - 40)
Exhaust front tube to three way catalyst 51.0 - 64.7 (5.2 - 6.5, 38 - 47) C
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
Unit: N·m (kg-m, ft-lb) E
Exhaust system connections
Exhaust manifold to exhaust front tube 59.8 - 69.6 (6.1 - 7.0, 45 - 51)
Exhaust front tube to exhaust tube 51.0 - 64.7 (5.2 - 6.5, 38 - 47) F
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