2004 ISUZU TF SERIES catalytic converter

ENGINE EXHAUST 6F-1
SECTION 6F
ENGINE EXHAUST
CONTENTS
PAGE
General Description........................................................................................................ 6F- 2
Service Precaution ......................................................................................................... 6F- 4
Exhaust Pipe ................................................................................................................... 6F- 5
Exhaust pipe and Associated parts.......................................................................... 6F- 5
Removal ...................................................................................................................... 6F- 5
Installation .................................................................................................................. 6F- 6
Inspection ................................................................................................................... 6F- 6
Front Exhaust Pipe ......................................................................................................... 6F- 7
Front Exhaust Pipe and Associated Parts ............................................................... 6F- 7
Removal ...................................................................................................................... 6F- 7
Installation .................................................................................................................. 6F- 7
Mid Pipe ........................................................................................................................... 6F- 8
Mid Pipe and associated Parts ................................................................................. 6F- 8
Removal ...................................................................................................................... 6F- 8
Installation .................................................................................................................. 6F- 8
Catalytic Converter (If applicable) ................................................................................. 6F- 9
Catalytic Converter and Associated Parts ............................................................... 6F- 9
Removal ...................................................................................................................... 6F- 9
Installation .................................................................................................................. 6F- 9
3 way Catalytic Converter System ............................................................................ 6F- 10
Exhaust Silencer ............................................................................................................. 6F- 12
Exhaust Silencer and Associated Parts ................................................................... 6F- 12
Removal ...................................................................................................................... 6F- 12
Installation .................................................................................................................. 6F- 13
Main Data and Specifications ........................................................................................ 6F- 14
Torque Specification.................................................................................................. 6F- 15

ENGINE EXHAUST 6F-3





























When inspecting or replacing exhaust system components,
make sure there is adequate clearance from all points on the
underbody to prevent overheating the floor pan and possible
damage to the passenger compartment insulation and trim
materials.
Check complete exhaust system and nearby body areas and
rear compartment lid for broken, damaged, missing or
mispositioned parts, open seams, holes, loose connections or
other deterioration which could permit exhaust fumes to seep
into the rear compartment or passenger compartment. Dust or
water in the rear compartment may be an indication of a
problem in one of these areas. Any faulty areas should be
corrected immediately.
Hangers
Various types of hangers are used to support exhaust
system(s). These include conventional rubber straps, rubber
rings, and rubber blocks.
The installation of exhaust system supports is very important,
as improperly installed supports can cause annoying vibrations
which can be difficult to diagnose.
Three Way Catalytic Converter (If applicable)
The three way catalytic converter is an emission control device
added to the exhaust system to reduce pollutants from the
exhaust gas stream.

CAUTION: The catalytic converter requires the use of
unleaded fuel only.
Periodic maintenance of the exhaust system is not required. If
the vehicle is raised for other service, it is advisable to check
the condition of the complete exhaust system.
A dual bed monolith catalytic converter is used in combination
with three way catalytic converter.
Catalytic Types:
Three way (Reduction/Oxidation) catalyst
The catalyst coating on the three way (reduction) converter
contains platinum and rhodium which lowers the levels of
nitrous oxide (NOx) as well as hydrocarbons (HC) and carbon
monoxide (Co).
Gasket
The gasket must be replaced whenever a new exhaust pipe,
muffler or catalytic converter is installed.

ENGINE EXHAUST 6F-5
Exhaust Pipe
Exhaust Pipe and Associated parts





RTW46FLF000401













Removal
(2.4L)
CAUTION
When you remove or install the front exhaust pipe, make
sure not to damage the fuel evaporative pipe.
1. Damper rubber
2. Exhaust silencer
3. Mid pipe
4. Damper rubber
5. Front exhaust pipe fixing nut
6. Catalytic converter (If applicable)
7. Front exhaust pipe

6F-6 ENGINE EXHAUST


Installation
To install, follow the removal steps in the reverse order.










Important - Installation
1. Front Exhaust Pipe Flange Nut
Connect the exhaust pipe to the exhaust manifold.
Front exhaust pipe to manifold nut.
Torque

N
m (kgf
m)
28 (2.9)
Inspection
Make the necessary adjustments, and part replacements if
excessive wear or damage is discover during inspection.

1. Front Exhaust Pipe
2. Center Exhaust Pipe and Catalytic Converter Flange Nut
3. Exhaust Pipe Damper Rubber
4. Exhaust Silencer with Rear Exhaust Pipe

Check the pipes for for corrosion, cracking , damage or
misalignment and repair if required.
Check the damper rubber for deterioration or damage and
repair if required.

ENGINE EXHAUST 6F-7
Front Exhaust Pipe (W/O Catalytic
Converter)
Front Exhaust Pipe and Associated Parts





RTW46F000101
Legend
1. Front Exhaust Pipe Fixing Nuts
2. Front Exhaust Pipe
3. Mid Exhaust Pipe Fixing Nuts










Removal
(2.4L)
1. Disconnect battery ground cable.
2. Raise the vehicle and support with suitable safety stands.
3. Remove the front exhaust pipe fixing nuts (1).
4. Remove mid pipe fixing nuts (3).
5. Remove front exhaust pipe (2).




Installation
1. Install front exhaust pipe (2) and tighten four nuts (1).
Torque:
Nuts: 28 N




m (2.9 kgf




m)
2. Tighten two nuts (3).
Torque: 43 N




m (4.4 kgf




m)

ENGINE EXHAUST 6F-9
Catalytic Converter (If applicable)
Catalytic Converter and Associated Parts





RTW46FSF000301
Legend
1. Catalytic Converter
2. O
2 Sensor Converter
3. Front Pipe Fixing Nuts
4. Mid Pipe Fixing Nuts








Removal
(2.4L)
1. Disconnect battery ground cable.
2. Raise the vehicle and support with suitable safety stands.
3. Remove front pipe fixing nuts (3).
4. Remove mid pipe fixing nuts (4).
5. Remove the O
2 sensor connector (2).
6. Remove the front exhaust pipe with catalytic converter (1).





Installation
1. Install Catalytic Converter (1) and tighten four to the
specified torque:
Torque:
Fixing nuts: 28 N




m (2.9 kgf




m)
2. Tight two nuts (4)
Torque:
Nuts: 43 N




m (4.4 kgf




m)
3. Connect the O
2 sensor connector (2).

6F-10 ENGINE EXHAUST
3 WAY CATALYTIC CONVERTER
SYSTEM (If applicable)

N2



Inspection
Make the necessary adjustments, and part replacements if
excessive or damage is discovered during inspection.

Exhaust Pipe Assembly
1. Check connections for looseness or damage.
2. Check clamps for weakness, crack, or damage.


Catalytic Converter
Check for dents or damage.
If any part of the converter is damaged or dented, repair or
replace it.


Removal
1. Jack up the vehicle.
2. Check that the converter is cool.
3. Remove the bolts at the front and rear of the converter.
4. Remove the converter and gaskets.

6F-14 ENGINE EXHAUST
Main Data and Specifications

Exhaust system
Pipe outside diameter ✕ thickness
Front pipe mm(in) 44.5 ✕ 1.5 (1.75✕0.059)
Middle pipe mm(in) 50.8 ✕ 1.5 (2.00 ✕ 0.059)
Rear pipe mm(in) 50.8 ✕ 1.5 (2.0 ✕ 0.059)

Silencer
Type Circular section-shell construction
of triple; double skin and end plates, internal
construction of baffles
and perforated tubes.

Number of suspension points
Type
Catalytic converter type (If applicable) 4
Rubber
Three way Catalytic Converter