SAFARI

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EXHAUSTSYSTEM-2.2LDICOR
Maintenance of Closed Coupled Catalytic
Converter (ccc)
Closed Coupled Catalytic Converter should be flushed
by giving full throttle (4 to 5 times) in standing
condition of vehicle on daily basis. In addition to this
it is recommended to run the vehicle at high speeds
(80 to 100 kmph) for few km as this will help to flush
the carbon soot deposits from exhaust system and
ccc. High speed running of the vehicle may be done
periodically to avoid chocking of ccc.
Alternatively flushing operation for cleaning the
catalytic converter can be done by dry compressed
air draft (3 to 4 bars) directed on the honeycomb
structure of catalytic converter (after removing from
vehicle)
Avoid :
l Push start or tow starting the vehicle. (Use jump
leads).
l Long (not more than 10 seconds) repeat (not more
than 3 times) starting of the vehicle. Investigate
the cause for difficulty in starting and rectify the
same.
l Long idling (to warm-up). If the engine is running
rough, after a cold start.
l Switching “OFF” the ignition when driving down the
hill.
l Fuel tank getting almost empty.
l Pre- Coating/Painting of Catalytic Converter.
ParkingWarning :
Avoid parking the vehicle over inflammable materials,
such as dry leaves, grass, etc. as the exhaust system is
hot enough to initiate “FIRE”.
EXHAUSTPIPE(Front)
For replacement of exhaust pipe, be sure to hoist
vehicle and observeWARNINGunder “Maintenance”.
Removal
l Disconnect the front exhaust pipe at Close Coupled
Catalytic Converter (ccc) end by removing the 3
bolts.
l Similarly disconnect at pre-silencer end.
l Remove the front exhaust pipe assly.
Inspection
l Check for damages
l Check the condition of rubber hangers. Replace if
required.
Fitment
l Guide the front ehaust pipe in rubber hanger.
l Slightly tighten the mounting bolts at ccc end & at
pre-silencer end.
l Tighten the mounting bolts to specified torque.
General Maintenance
To avoid the danger of being burned, do not touch
the exhaust systemwhen the system is hot. Any service
on the exhaust system should be performed when the
system is cool.
At every interval of periodic maintenance service, and
when vehicle is raised for other service, check exhaust
systemas follows :
l Check rubber mountings for damage,
deterioration,and out of position.
l Keep sufficient clearance between exhaust system
components and underbody or adjust parts.
l Check exhausts system for leakage, loose
connection, dent and damage.
l If bolts or nuts are loosened, tighten them to
specified torque.
l Check nearby body areas for damage, missing or
mispositioned part, open seam, hole, loose
connection or any other defect which could permit
exhaust fumes to seep into vehicle.
NOTE:
l For disassembly and assembly of pre-silencer, main
silencer and post silencer, lift the vehical on a lift.
Refer the exploded view given in this section for
the fitment details / sequence.
l Tighten the mounting bolts & nuts to specified
torque when re-assembling.
l After installation start the engine and check each
joint of exhaust system for leakages.