Exhaust System: Section

EXHAUST SYSTEM
B ENGINE
SECTION
EXHAUST SYSTEM
EX EX
E
CONTENTS
PREPARATION ........................................................... 2 REMOVAL ............................................................. 4 F
Commercial Service Tools ........................................ 2 INSTALLATION ..................................................... 4
EXHAUST SYSTEM ................................................... 3 Inspection After Installation ...................................... 4
Checking Exhaust System ....................................... 3 SERVICE DATA AND SPECIFICATIONS (SDS) ........ 5 G
Removal and Installation .......................................... 3 Tightening Torque ..................................................... 5
Revision; 2004 April EX-1 2003 G35 Coupe

PREPARATION
PREPARATION PFP:00002
Commercial Service Tools ABS002YD
Tool name Description
Power tool Loosening nuts and bolts
PBIC0190E

EXHAUST SYSTEM
EXHAUST SYSTEM PFP:20100

A
Checking Exhaust System ABS004SD
Check exhaust pipes, muffler and mounting for improper attachment,

leaks, cracks, damage or deterioration. EX
SMA211A
E
Removal and Installation ABS004SE
CAUTION:
● Be sure to use genuine exhaust system parts or equivalents which are specially designed for heat F
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.
G
● Be careful not to cut your hand on the insulator edge.
PBIC2037E
1. Mounting rubber 2. Main muffler mounting bracket 3. Main muffler

4. Ring gasket 5. Mounting bracket 6. Center muffler
7. Collar 8. Grommet 9. Exhaust mounting bracket
10. Gasket 11. Exhaust front tube

EXHAUST SYSTEM
REMOVAL
● Disconnect each joint and mounting using power tool.
● When removing main muffler, remove main muffler mounting bracket bolts.
INSTALLATION
● Tighten main muffler mounting bracket bolts in order shown in
the figure.
PBIC1675E
When reassembling main muffler only.

● Temporarily tighten flange connecting center muffler to main
muffler (A).
● Move main muffler front / rear / left / right so that clearance
between tail tube and dumper is even.
● Fully tighten (A) to the specified torque.
When reassembling center muffler.
● Temporarily tighten all connecting flanges (A) (B).
● Move main muffler front / rear / left / right so that clearance
between tail tube and bumper is even. PBIC2104E
● Fully tighten connecting flanges to the specified torque.

When reassembling front tube.
● Temporarily tighten flange connecting center muffler to main muffler (A), flange connecting front tube to
center muffler (B), flange connecting catalyst to front tube (C).
● Move main muffler front / rear / left / right so that clearance between tail tube and bumper is even.
● Tighten connecting flanges in order of (A), (B), and (C) to the specified torque.
CAUTION:
● Always replace exhaust tube 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 insu-
lator, 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 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.
Inspection After Installation ABS004SF
Install in the reverse order of removal paying attention to the followings.

● Check clearance between tail tube and bumper is even.
● 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.

SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

A
Tightening Torque ABS004SG
Unit: N·m (kg-m, ft-lb)

Exhaust system connections
EX
Between three way catalyst and exhaust front tube 45.1 - 59.8 (4.6 - 6.1, 34 - 44)
Between exhaust front tube and center muffler 51.0 - 64.7 (5.2 - 6.5, 38 - 47)
Between center muffler and main muffler 30.4 - 39.2 (3.1 - 3.9, 23 - 28)
Three way catalyst mounting bracket 25.5 - 31.4 (2.6 - 3.2, 19 - 23) C
Center muffler mounting bracket 12.7 - 15.7 (1.3 - 1.6, 10 - 11)
Main muffler mounting bracket 12.7 - 15.7 (1.3 - 1.6, 10 - 11)

SERVICE DATA AND SPECIFICATIONS (SDS)

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EXHAUST SYSTEM

Revision; 2004 April EX-1 2003 G35 Coupe

Commercial Service Tools ABS002YD

Tool name Description

Power tool Loosening nuts and bolts

Revision; 2004 April EX-2 2003 G35 Coupe

EXHAUST SYSTEM PFP:20100

Check exhaust pipes, muffler and mounting for improper attachment,

1. Mounting rubber 2. Main muffler mounting bracket 3. Main muffler

Revision; 2004 April EX-3 2003 G35 Coupe

When reassembling main muffler only.

● Fully tighten connecting flanges to the specified torque.

Install in the reverse order of removal paying attention to the followings.

Revision; 2004 April EX-4 2003 G35 Coupe

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

Unit: N·m (kg-m, ft-lb)

Revision; 2004 April EX-5 2003 G35 Coupe

Revision; 2004 April EX-6 2003 G35 Coupe

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