Page 1905 of 4179
EX-1
EXHAUST SYSTEM
B ENGINE
CONTENTS
C
D
E
F
G
H
I
J
K
L
M
SECTION
A
EX
EXHAUST SYSTEM
EXHAUST SYSTEM ................................................... 2
Checking Exhaust System ....................................... 2
Removal and Installation .......................................... 2
QR20DE AND QR25DE ........................................ 2
YD22DDTI ............................................................. 3
REMOVAL ............................................................. 3
INSTALLATION ..................................................... 3
INSPECTION AFTER INSTALLATION ................. 4SERVICE DATA AND SPECIFICATIONS (SDS) ........ 5
Tightening Torque ..................................................... 5
QR20DE AND QR25DE ........................................ 5
YD22DDTI ............................................................. 5
Page 1906 of 4179
EX-2
EXHAUST SYSTEM
EXHAUST SYSTEMPFP:20100
Checking Exhaust SystemEBS00AZ6
Check exhaust pipes, muffler and mounting for improper attachment,
leaks, cracks, damage or deterioration.
If anything is found, repair or replace damaged parts.
Removal and InstallationEBS003DN
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
SMA211A
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
SBIA0434E
Page 1907 of 4179

EXHAUST SYSTEM
EX-3
C
D
E
F
G
H
I
J
K
L
MA
EX
YD22DDTI
REMOVAL
Separate each connection as necessity.
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
Always replace exhaust gaskets and seal bearings with new ones when reassembling.
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.
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
10. Exhaust center tube 11. Gasket 12. Seal bearing
PBIC2440E
Page 1908 of 4179
EX-4
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.
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.
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.
PBIC2274E
PBIC2275E
Page 1909 of 4179

SERVICE DATA AND SPECIFICATIONS (SDS)
EX-5
C
D
E
F
G
H
I
J
K
L
MA
EX
SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
Tightening TorqueEBS00KP4
QR20DE AND QR25DE
Unit: N·m (kg-m, ft-lb)
YD22DDTI
Unit: N·m (kg-m, ft-lb) Exhaust system connections
Exhaust manifold three way catalyst assembly to exhaust front
tube43.1 - 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)
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)
Mounting bolts and nuts M8 12.7 - 15.7 (1.3 - 1.6, 10 - 11)
Exhaust system connections
Catalyst rear diffuser 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)
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)
Mounting bolts and nuts M8 12.7 - 15.7 (1.3 - 1.6, 10 - 11)
Page 1910 of 4179
EX-6
SERVICE DATA AND SPECIFICATIONS (SDS)
Page 1911 of 4179
ACC-1
ACCELERATOR CONTROL SYSTEM
B ENGINE
CONTENTS
C
D
E
F
G
H
I
J
K
L
M
SECTION
A
ACC
ACCELERATOR CONTROL SYSTEM
ACCELERATOR CONTROL SYSTEM ...................... 2
Removal and Installation .......................................... 2
REMOVAL ............................................................. 2
INSTALLATION ..................................................... 2
INSPECTION AFTER INSTALLATION ................. 2SERVICE DATA AND SPECIFICATIONS (SDS) ........ 3
Tightening Torque ..................................................... 3
Page 1912 of 4179

ACC-2
ACCELERATOR CONTROL SYSTEM
ACCELERATOR CONTROL SYSTEMPFP:18005
Removal and InstallationEBS00KP5
REMOVAL
1. Disconnect accelerator pedal position sensor harness connector.
2. Loosen nuts, and remove accelerator pedal assembly.
CAUTION:
Do not disassemble accelerator pedal assembly. Do not remove accelerator pedal position sen-
sor from accelerator pedal assembly.
Avoid impact from dropping etc. during handling.
Be careful to keep accelerator pedal assembly away from water.
Do not adjust adjusting screw (painted white).
INSTALLATION
Install in the reverse order of removal.
INSPECTION AFTER INSTALLATION
Make sure that accelerator pedal moves smoothly within the whole operation range.
Make sure that accelerator pedal securely returns to the original position.
For the electrical inspection of accelerator pedal position sensor, refer to EC-386, "DTC P2122, P2123
APP SENSOR" , EC-393, "DTC P2127, P2128 APP SENSOR" , EC-409, "DTC P2138 APP SENSOR"
[QR (WITH EURO-OBD)], EC-740, "DTC P2122, P2123 APP SENSOR" , EC-747, "DTC P2127, P2128
APP SENSOR" , EC-763, "DTC P2138 APP SENSOR" [QR (WITHOUT EURO-OBD)] or EC-987, "DTC
P0122, P0123 APP SENSOR" , EC-1025, "DTC P0222, P0223 APP SENSOR" , EC-1149, "DTC P2135
APP SENSOR" [YD (WITH EURO-OBD)], EC-1297, "DTC P0122, P0123 APP SENSOR" , EC-1332,
"DTC P0222, P0223 APP SENSOR" , EC-1437, "DTC P2135 APP SENSOR" [YD (WITHOUT EURO-
OBD)].
CAUTION:
When the harness connector of the accelerator pedal position sensor is disconnected, perform
“Accelerator Pedal Released Position Learning”. (QR20DE and QR25DE) Refer to EC-45, "
Acceler-
ator Pedal Released Position Learning" (WITH EURO-OBD) or EC-507, "Accelerator Pedal
Released Position Learning" (WITHOUT EURO-OBD).
NOTE:
In the case of YD22DDTi, it is unnecessary to perform “Accelerator Pedal Released Position Learning”
even when disconnecting the harness connector of the accelerator pedal position sensor.
1. Accelerator pedal assembly
PBIC2412E