ENGINE

SECTION

EX

EXHAUST SYSTEM

A

EX

C

D

E

CONTENTS

F

HR12DE, HR15DE

K9K

PRECAUTION ............................................... 2

PRECAUTION ............................................... 8

PRECAUTIONS ................................................... 2

PRECAUTIONS .................................................. 8

Removal and Installation ........................................... 2

Removal and Installation .......................................... 8

PREPARATION ............................................ 3

PREPARATION ............................................ 9

PREPARATION ................................................... 3

PREPARATION .................................................. 9

Special Service Tools ................................................ 3
Commercial Service Tools ........................................ 3

Commercial Service Tools ........................................ 9

PERIODIC MAINTENANCE .......................... 4

REMOVAL AND INSTALLATION ................ 5

H

I

PERIODIC MAINTENANCE ........................ 10
EXHAUST SYSTEM .......................................... 10


EXHAUST SYSTEM ............................................ 4
Inspection .................................................................. 4

G

J

Inspection ................................................................10

REMOVAL AND INSTALLATION ............... 11

K

EXHAUST SYSTEM .......................................... 11

EXHAUST SYSTEM ............................................ 5
Exploded View .......................................................... 5
Removal and Installation ........................................... 6
Inspection .................................................................. 7

Exploded View .........................................................11
Removal and Installation .........................................11
Inspection ................................................................12

L

M

N


O

P

Revision: 2012 July

EX-1

N17


PRECAUTIONS
[HR12DE, HR15DE]

< PRECAUTION >

PRECAUTION
PRECAUTIONS
Removal and Installation

INFOID:0000000006657876

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 heat insulator edge.


Revision: 2012 July

EX-2

N17


PREPARATION
[HR12DE, HR15DE]

< PREPARATION >

PREPARATION

A

PREPARATION
Special Service Tools

INFOID:0000000006657877

Tool number
Tool name
KV10114400
Heated oxygen sensor wrench

EX

Description


C

Loosening or tightening heated oxygen sensor 2
a: For 22 mm (0.87 in) width hexagon nut

D

E
S-NT636

Commercial Service Tools

INFOID:0000000006657878

Tool name

Description

Power tool

Loosening nuts and bolts

F

G

H

I
PBIC0190E


Heated oxygen sensor thread cleaner

JPBIA0238ZZ

Reconditioning the exhaust system threads
before installing a new heated oxygen sensor
(Use with anti-seize lubricant shown below.)
A: For zirconia heated oxygen sensor [18
mm (0.71 in) dia.]
B: For titania heated oxygen sensor [12
mm (0.47 in) dia.]
C: Mating surface shave cylinder
D: Flutes
Lubricating heated oxygen sensor thread
cleaner when reconditioning exhaust system
threads

Anti-seize lubricant (Permatex 133AR
or equivalent meeting MIL specification MIL-A-907)

J

K

L

M

N

AEM489

O

P

Revision: 2012 July

EX-3

N17


EXHAUST SYSTEM
[HR12DE, HR15DE]

< PERIODIC MAINTENANCE >

PERIODIC MAINTENANCE
EXHAUST SYSTEM
Inspection

INFOID:0000000006657879

Check exhaust pipes, muffler, and mounting for improper attachment, leakage, cracks, damage or deterioration.
• If anything is found, repair or replace damaged parts.

SMA211A

Revision: 2012 July


EX-4

N17


EXHAUST SYSTEM
[HR12DE, HR15DE]

< REMOVAL AND INSTALLATION >

REMOVAL AND INSTALLATION

A

EXHAUST SYSTEM
Exploded View

INFOID:0000000006657880

EX

HR12DE
C

D

E

F


G

H

I

J

JPBIA5709GB

1.

Seal bearing

2.

Spring

3.

Heated oxygen sensor 2

4.

Exhaust front tube

5.

Seal bearing


6.

Mounting rubber

7.

Center muffler

8.

Ring gasket

9.

Main muffler

K

: Always replace after every disassembly.

L

: N·m (kg-m, in-lb)
: N·m (kg-m, ft-lb)

M

N


O

P

Revision: 2012 July

EX-5

N17


EXHAUST SYSTEM
[HR12DE, HR15DE]

< REMOVAL AND INSTALLATION >
HR15DE

JSBIA2100GB

1.

Heated oxygen sensor 2

2.

Catalyst cover (upper)

3.

Seal bearing


4.

Catalyst cover (lower)

5.

Spring

6.

Spring

7.

Mounting rubber

8.

Main muffler

9.

Ring gasket

10. Center muffler

11. Mounting rubber

12. Seal bearing


13. Exhaust front tube
: Always replace after every disassembly.
: N·m (kg-m, in-lb)
: N·m (kg-m, ft-lb)

Removal and Installation

INFOID:0000000006657881

REMOVAL
• Disconnect each joint and mounting.
• Remove heated oxygen sensor 2 with following procedure:
- Using heated oxygen sensor wrench [SST: KV10114400] (A),
removal heated oxygen sensor 2 (1).
CAUTION:
• Discard any heated oxygen sensor which has been dropped
from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one.
• Before installing new heated oxygen sensor, clean exhaust
system threads using Oxygen Sensor Thread Cleaner (commercial service tool) and approved Anti-seize lubricant
(commercial servicetool).
JPBIA3468ZZ

INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
• Always replace seal bearings and gasket with new ones when reassembling.
Revision: 2012 July

EX-6


N17


EXHAUST SYSTEM
[HR12DE, HR15DE]
< REMOVAL AND INSTALLATION >
• Discard any heated oxygen sensor 2 which has been dropped onto a hard surface such as a concrete floor. Use a new one.
A
• Before installing a new heated oxygen sensor 2, clean exhaust system threads using the heated oxygen sensor thread cleaner (commercial service tool) and apply anti-seize lubricant (commercial service tool).
EX
• Never over torque heated oxygen sensor 2. Doing so may cause damage to the heated oxygen sensor 2, resulting in the “MIL” coming on.
• Prevent rust preventives from adhering to the sensor body.
• If heat insulator is badly deformed, repair or replace it. If deposits such as mud pile up on the heat C
insulator, remove them.
• When installing heat insulator avoid large gaps or interference between heat insulator and each
exhaust pipe.
D
• Remove deposits from the sealing surface of each connection. Connect them securely to avoid gas
leakage.
• Temporarily tighten mounting nuts and bolts. Check each part for unusual interference and mountE
ing rubber interference, and then tighten them to the specified torque.
• When installing each mounting rubber, avoid twisting or unusual extension in up/down, front/rear
and right/left directions.
F

Exhaust Manifold to Exhaust Front Tube

1.


Securely insert seal bearing (2) into exhaust manifold (1) side in
the direction shown in the figure.
G

2.

3.

3

: Spring

4

: Bolt

5

: Exhaust front tube

H

CAUTION:
Never damage seal bearing surface when installing.
With spring, tighten bolt.
CAUTION:
• Ensure springs are seated correctly on the flange and not
sitting on (A).
• Be careful that bolt does not interfere with mounting hole of exhaust front tube.
After installing, check that bolt does not interfere with mounting hole of exhaust front tube.


I
JPBIA3652ZZ

J

K

Exhaust Front Tube to Center Muffler

1.

Securely insert seal bearing (2) into exhaust front tube (1) side
in the direction shown in the figure.
L

2.

3.

3

: Spring

4

: Bolt

5


: Center muffler

M

CAUTION:
Never damage seal bearing surface when installing.
With spring, tighten bolt.
CAUTION:
• Ensure springs are seated correctly on the flange and not
sitting on (A).
• Be careful that bolt does not interfere with mounting hole of center muffler.
After installing, check that bolt does not interfere with mounting hole of center muffler.

Inspection

N
JPBIA3652ZZ

O

INFOID:0000000006657882

INSPECTION AFTER INSTALLATION
• Check clearance between tail tube and rear bumper is even.
• With 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.
Revision: 2012 July

EX-7


N17

P


PRECAUTIONS
[K9K]

< PRECAUTION >

PRECAUTION
PRECAUTIONS
Removal and Installation

INFOID:0000000007838729

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 heat insulator edge.

Revision: 2012 July

EX-8

N17



PREPARATION
[K9K]

< PREPARATION >

PREPARATION

A

PREPARATION
Commercial Service Tools

INFOID:0000000007838730

Tool name

Description

Power tool

Loosening nuts and bolts

EX

C

D

E

PBIC0190E

F

G

H

I

J

K

L

M

N

O

P

Revision: 2012 July

EX-9

N17



EXHAUST SYSTEM
[K9K]

< PERIODIC MAINTENANCE >

PERIODIC MAINTENANCE
EXHAUST SYSTEM
Inspection

INFOID:0000000007838731

Check exhaust pipes, muffler, and mounting for improper attachment, leakage, cracks, damage or deterioration.
• If anything is found, repair or replace damaged parts.

SMA211A

Revision: 2012 July

EX-10

N17


EXHAUST SYSTEM
[K9K]

< REMOVAL AND INSTALLATION >

REMOVAL AND INSTALLATION


A

EXHAUST SYSTEM
Exploded View

INFOID:0000000007838732

EX

C

D

E

F

G

H

I

J

JSBIA2022GB

1.


Seal bearing

2.

Spring

3.

Exhaust front tube

4.

Mounting rubber

5.

Gasket

6.

Center tube

7.

Ring gasket

8.

Main muffler


K

: Always replace after every disassembly.

L

: N·m (kg-m, ft-lb)

Removal and Installation

INFOID:0000000007838733

M

REMOVAL
• Disconnect each joint and mounting.
N

INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
• Always replace seal bearings and gasket with new ones when reassembling.
• Remove deposits from the sealing surface of each connection. Connect them securely to avoid gas
leakage.
• Temporarily tighten mounting nuts and bolts. Check each part for unusual interference and mounting rubber interference, and then tighten them to the specified torque.
• When installing each mounting rubber, avoid twisting or unusual extension in up/down, front/rear
and right/left directions.
Exhaust Manifold to Exhaust Front Tube

Revision: 2012 July


EX-11

N17

O

P


EXHAUST SYSTEM
< REMOVAL AND INSTALLATION >
1. Securely insert seal bearing (2) into exhaust manifold (1) side in
the direction shown in the figure.

2.

3.

3

: Spring

4

: Bolt

5

: Exhaust front tube


CAUTION:
Be careful not to damage seal bearing surface when installing.
With spring, tighten bolt.
CAUTION:
• Ensure springs are seated correctly on the flange and not sitting on (A).
• Be careful that bolt does not interfere with mounting hole of exhaust front tube.
After installing, check that bolt does not interfere with mounting hole of exhaust front tube.

Inspection

[K9K]

JPBIA3652ZZ

INFOID:0000000007838734

INSPECTION AFTER INSTALLATION
• Check clearance between tail tube and rear bumper is even.
• With engine running, check exhaust tube joints f