Exhaust System: Service and Repair

Removal and Installation

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.

REMOVAL
^ Disconnect each joint and mounting with power tool.
^ When removing main muffler, remove main muffler mounting bracket bolts.
^ For removing and installing parts around propeller shaft, be careful of the following caution.

CAUTION: Be sure to prevent propeller shaft from interfering parts and tools. If necessary, install protector to propeller shaft to prevent damage.
For propeller shaft protector, refer to "REAR PROPELLER SHAFT".

INSTALLATION
Note the following, and install in the reverse order of removal.





^ Tighten main muffler mounting bracket bolts in numerical order as shown in the figure.

When reassembling main muffler only.





1. Temporarily tighten connecting flange (A).
2. Move main muffler front / rear / left / right so that clearance between tail tube and bumper is even.
3. Tighten connecting flange (A) to the specified torque.

When reassembling center muffler.
1. Temporarily tighten connecting flanges in order of (A) and (B).
2. Move main muffler front / rear / left / right so that clearance between tail tube and bumper is even.
3. Tighten connecting flanges in order of (A) and (B) to the specified torque.

When reassembling exhaust front tube.
1. Temporarily tighten connecting flanges of center muffler in order of (B) and (C).
2. Move main muffler front / rear / left / right so that clearance between tail tube and bumper is even.
3. Tighten connecting flanges in order of (B) and (C) to the specified torque.

CAUTION:
^ Always replace exhaust tube gaskets with new ones when reassembling. If heat insulator is badly deformed, repair or replace it. If deposits such as mud pile up on 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.
^ 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 rights left directions.

INSPECTION AFTER INSTALLATION
^ Make sure that clearance between tail tube and bumper is even.
^ With engine running, check exhaust tube joints for gas leakage and unusual noises.
^ Make sure that mounting brackets and mounting rubbers are installed properly and free from undue stress. Improper installation could result in excessive noise and vibration.