ENGINE
SECTION
EXHAUST SYSTEM
EX EX
E
CONTENTS
HR12DE Sealant or/and Lubricant .......................................... 3 F
PRECAUTION ............................................... 2 PERIODIC MAINTENANCE ......................... 4
EXHAUST SYSTEM ........................................... 4 G
PRECAUTIONS ................................................... 2
Removal and Installation ........................................... 2 Inspection ................................................................. 4
Precautions for Removing Battery Terminal ............. 2
REMOVAL AND INSTALLATION ................ 5 H
PREPARATION ............................................ 3
EXHAUST SYSTEM ........................................... 5
PREPARATION ................................................... 3 Exploded View .......................................................... 5
Removal and Installation .......................................... 5 I
Special Service Tools ................................................ 3
Commercial Service Tools ........................................ 3 Inspection ................................................................. 9
Revision: 2014 August EX-1 AD0
PRECAUTIONS
< PRECAUTION > [HR12DE]
PRECAUTION
PRECAUTIONS
Removal and Installation INFOID:0000000010041516
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.
Precautions for Removing Battery Terminal INFOID:0000000010041517
• When removing the 12V battery terminal, turn OFF the ignition
switch and wait at least 30 seconds.
NOTE:
ECU may be active for several tens of seconds after the ignition
switch is turned OFF. If the battery terminal is removed before ECU
stops, then a DTC detection error or ECU data corruption may
occur.
• For vehicles with the 2-batteries, be sure to connect the main bat-
tery and the sub battery before turning ON the ignition switch.
NOTE:
If the ignition switch is turned ON with any one of the terminals of
SEF289H
main battery and sub battery disconnected, then DTC may be
detected.
• After installing the 12V battery, always check "Self Diagnosis Result" of all ECUs and erase DTC.
NOTE:
The removal of 12V battery may cause a DTC detection error.
Revision: 2014 August EX-2 AD0
PREPARATION
< PREPARATION > [HR12DE]
PREPARATION A
PREPARATION
Special Service Tools INFOID:0000000010041518
EX
Tool number
Description C
Tool name
KV10114400 Loosening or tightening heated oxygen sen-
Heated oxygen sensor wrench sor 2
: For 22 mm (0.87 in) width hexagon nut D
E
JPBIA0397ZZ
Commercial Service Tools INFOID:0000000010041519 F
Tool name Description
G
Power tool Loosening nuts and bolts
I
PBIC0190E
Heated oxygen sensor thread cleaner Reconditioning the exhaust system threads
before installing a new heated oxygen sensor J
(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 K
mm (0.47 in) dia.]
: Mating surface shave cylinder
JPBIA0238ZZ
: Flutes
L
Sealant or/and Lubricant INFOID:0000000010586965
M
Tool name Description
Anti-seize lubricant (Permatex 133AR Lubricating heated oxygen sensor thread
or equivalent meeting MIL specifica- cleaner when reconditioning exhaust system N
tion MIL-A-907) threads
AEM489
Revision: 2014 August EX-3 AD0
EXHAUST SYSTEM
< PERIODIC MAINTENANCE > [HR12DE]
PERIODIC MAINTENANCE
EXHAUST SYSTEM
Inspection INFOID:0000000010041520
Check exhaust pipes, muffler, and mounting for improper attach-
ment, leakage, cracks, damage or deterioration.
• If anything is found, repair or replace damaged parts.
SMA211A
Revision: 2014 August EX-4 AD0
EXHAUST SYSTEM
< REMOVAL AND INSTALLATION > [HR12DE]
REMOVAL AND INSTALLATION A
EXHAUST SYSTEM
Exploded View INFOID:0000000010041521
EX
JSBIA5050GB J
Mounting rubber (Rear) Main muffler Mounting rubber
Heated oxygen sensor 2 Seal bearing Spring K
: Vehicle front
: Always replace after every disassembly.
L
: N·m (kg-m, ft-lb)
Removal and Installation INFOID:0000000010041522
M
REMOVAL
1. Remove rear bumper. Refer to EXT-38, "Removal and Installation". N
2. Remove rear RH wheel. Refer to WT-5, "Removal and Installation".
3. Remove heated oxygen sensor 2 with following procedure:
• Using heated oxygen sensor wrench [SST: KV10114400] (A), O
removal heated oxygen sensor 2 .
CAUTION:
• Discard any heated oxygen sensor which has been
P
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
Revision: 2014 August EX-5 AD0
EXHAUST SYSTEM
< REMOVAL AND INSTALLATION > [HR12DE]
4. Remove the main muffler mounting bolts .
JSBIA4909ZZ
5. Use the transmission jack (A) to support the rear suspension
trailing arm.
JSBIA4910ZZ
6. Remove the rear suspension trailing arm bolt . Refer to RSU-14, "Exploded View".
: Vehicle front
JSBIA4911ZZ
7. Slowly lower the transmission jack about length (L) between
center of rear trailing arm bolt hole and rear wheel arch hole
.
: Vehicle front
L : 90 mm
JSBIA4912ZZ
8. Remove the main muffler mounting rubbers .
: Vehicle front
JSBIA4913ZZ
Revision: 2014 August EX-6 AD0
EXHAUST SYSTEM
< REMOVAL AND INSTALLATION > [HR12DE]
9. Pull the main muffler towards rear side and rotate till the main
muffler stands straight. A
EX
JSBIA4914ZZ
D
10. Remove the main muffler with following procedure:
a. Move the main muffler lower side under the suspension mem-
ber. E
b. Pull the main muffler towards the vehicle front side, In the direc-
tion of arrow as shown in figure.
F
: Vehicle front
G
JSBIA4915ZZ
INSTALLATION H
Note the following, and install in the reverse order of removal.
CAUTION:
• Always replace seal bearings with new ones when reassembling.
• Discard any heated oxygen sensor 2 which has been dropped onto a hard surface such as a con- I
crete floor. Use a new one.
• Before installing a new heated oxygen sensor 2, clean exhaust system threads using the heated oxy-
gen sensor thread cleaner (commercial service tool) and apply anti-seize lubricant (commercial ser- J
vice tool).
• Never over torque heated oxygen sensor 2. Doing so may cause damage to the heated oxygen sen-
sor 2, resulting in the “MIL” coming on.
• Remove deposits from the sealing surface of each connection. Connect them securely to avoid gas K
leakage.
• When installing each mounting rubber, use silicon oil to avoid twisting.
• Temporarily tighten mounting bolts. Check each part for unusual interference and mounting rubber L
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.
M
Install seal bearing according to the following instructions.
CAUTION:
N
Revision: 2014 August EX-7 AD0
EXHAUST SYSTEM
< REMOVAL AND INSTALLATION > [HR12DE]
The structure of seal bearing depends on the mounting portion.
When installing seal bearings, be careful not to install wrong
one.
: Exhaust manifold side
: Mesh
: Exhaust main muffler side
: Pawl (projection)
JPBIA6287ZZ
Exhaust Manifold to Main muffler
1. Place a piece of wood (A) on seal bearing and securely insert
the seal bearing on the exhaust manifold side, using a plastic
hammer (B).
CAUTION:
• Never damage the seal bearing surface during insertion.
• If seal bearing is inserted by hammering directly without
using a piece of wood, the seal bearing is deformed and
exhaust gas leaks. To insert seal bearing, always use a
piece of wood and insert straight.
JPBIA6288ZZ
2. Check that seal bearing is in absolute contact with the
flange . If there is clearance , insert seal bearing straight by
hand to bring the seal bearing into absolute contact with the
flange.
CAUTION:
• Never use a tool for insertion.
• Never insert seal bearing by tightening exhaust main muf-
fler .
JPBIA6289ZZ
Revision: 2014 August EX-8 AD0
EXHAUST SYSTEM
< REMOVAL AND INSTALLATION > [HR12DE]
3. With spring , tighten bolt .
A
: Exhaust manifold
: Seal bearing
: Main muffler
EX
CAUTION:
• Fasten bolts to the flange of exhaust manifold side to the
C
specified torque.
• Ensure springs are seated correctly on the flange and not
sitting on . JSBIA4916ZZ
• Be careful that bolt does not interfere with mounting hole D
of exhaust main muffler ( ).
4. After installing, check the bolt does not interfere with mounting hole of exhaust main muffler.
5. Install rear mounting rubber as shown in figure. E
: Vehicle front
F
: Mounting rubber
: Identification mark
G
H
JSBIA5048ZZ
Inspection INFOID:0000000010041523
I
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. J
• 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.
K
Revision: 2014 August EX-9 AD0