ENGINE

SECTION
EXHAUST SYSTEM
EX EX

E
CONTENTS
HR16DE PREPARATION .................................................. 8 F
Special Service Tools ............................................... 8
PRECAUTION ............................................... 2 Commercial Service Tools ........................................ 8
G
PRECAUTIONS ................................................... 2 ON-VEHICLE MAINTENANCE ..................... 9
Removal and Installation ........................................... 2
EXHAUST SYSTEM ........................................... 9
PREPARATION ............................................ 3 Inspection ................................................................. 9 H

PREPARATION ................................................... 3 ON-VEHICLE REPAIR ................................. 10

Special Service Tools ................................................ 3
EXHAUST SYSTEM .......................................... 10 I
Commercial Service Tools ........................................ 3
Exploded View .........................................................10
ON-VEHICLE MAINTENANCE ..................... 4 Removal and Installation .........................................10
Inspection ................................................................11 J
EXHAUST SYSTEM ............................................ 4
K9K
Inspection .................................................................. 4
PRECAUTION .............................................. 13 K
ON-VEHICLE REPAIR .................................. 5
PRECAUTIONS ................................................. 13
EXHAUST SYSTEM ............................................ 5
Removal and Installation .........................................13
Exploded View .......................................................... 5 L
Removal and Installation ........................................... 5 ON-VEHICLE MAINTENANCE .................... 14
Inspection .................................................................. 6
MR20DE EXHAUST SYSTEM .......................................... 14
M
Inspection ................................................................14
PRECAUTION ............................................... 7
ON-VEHICLE REPAIR ................................. 15
PRECAUTIONS ................................................... 7 N
Removal and Installation ........................................... 7 EXHAUST SYSTEM .......................................... 15
Exploded View .........................................................15
PREPARATION ............................................ 8 Removal and Installation .........................................15
O
Inspection ................................................................16

EX-1
 PRECAUTIONS
< PRECAUTION > [HR16DE]

PRECAUTION
PRECAUTIONS
Removal and Installation INFOID:0000000000905770

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.

EX-2
 PREPARATION
< PREPARATION > [HR16DE]

PREPARATION A
PREPARATION
Special Service Tools INFOID:0000000000905778
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
S-NT636

Commercial Service Tools INFOID:0000000000905779 F

Tool name Description G

Heated oxygen sensor thread cleaner Reconditioning the exhaust system threads
before installing a new heated oxygen sensor
(Use with anti-seize lubricant shown below.) H
a: 18 mm (0.71 in) dia. for zirconia heated
oxygen sensor
b: 12 mm (0.47 in) dia. for titania heated ox-
ygen sensor I

AEM488

Anti-seize lubricant (Permatex 133AR Lubricating heated oxygen sensor thread J

or equivalent meeting MIL specifica- cleaner when reconditioning exhaust system
tion MIL-A-907) threads

AEM489
L

EX-3
 EXHAUST SYSTEM
< ON-VEHICLE MAINTENANCE > [HR16DE]

ON-VEHICLE MAINTENANCE
EXHAUST SYSTEM
Inspection INFOID:0000000000905773

Check exhaust pipes, muffler and mounting for improper attachment,

leaks, cracks, damage or deterioration.
• If anything is found, repair or replace damaged parts.

SMA211A

EX-4
 EXHAUST SYSTEM
< ON-VEHICLE REPAIR > [HR16DE]

ON-VEHICLE REPAIR A
EXHAUST SYSTEM
Exploded View INFOID:0000000000905774
EX

JPBIA0294GB K

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

4. Mounting rubber 5. Spring 6. Seal bearing L
7. Exhaust front tube 8. Heated oxygen sensor 2 9. Seal bearing
10. Stud bolt 11. Spring
Refer to GI-4, "Components" for symbols in the figure. M

Removal and Installation INFOID:0000000000905775

N
REMOVAL
• Disconnect each joint and mounting.
• Remove heated oxygen sensor 2 with following procedure.
- Using heated oxygen sensor wrench [SST: KV10114400] (A), O
removal heated oxygen sensor 2 (1).
CAUTION:
Be careful not to damage heated oxygen sensor 2. P

JPBIA0460ZZ

EX-5
 EXHAUST SYSTEM
< ON-VEHICLE REPAIR > [HR16DE]
INSTALLATION
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-
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 and apply anti-seize lubricant (commercial service tool).
• Never over torque heated oxygen sensor 2. Doing so may cause damage to the heated oxygen sen-
sor 2, resulting in the “MI” coming on.
• Remove deposits from the sealing surface of each connection. Connect them securely to avoid gas
leakage.
• When installing each mounting rubber, avoid twisting or unusual extension in up/down and right/left
directions.
• Temporarily tighten mounting nuts and bolts. Check each part for unusual interference, and then
tighten them to the specified torque.
Exhaust Manifold to Exhaust Front Tube
1. Securely insert seal bearing (2) into exhaust manifold (1) side in
the direction shown in figure.

3 : Spring
4 : Mounting nut
5 : Exhaust front tube
CAUTION:
Be careful not to damage seal bearing surface when install-
ing.
2. With spring, tighten mounting nut. PBIC3797E
• Be careful that mounting nut does not interfere with flanged
area ( ), and tighten it.
Exhaust Front Tube to Main Muffler
1. Securely insert seal bearing (2) into exhaust front tube (1) side
in the direction shown in figure.

3 : Spring
4 : Mounting bolt
5 : Main muffler
CAUTION:
Be careful not to damage seal bearing surface when install-
ing.
2. With spring, tighten mounting bolt. PBIC3798E
• Be careful that mounting bolt does not interfere with flanged
area ( ), and tighten it.
Inspection INFOID:0000000000905776

INSPECTION AFTER INSTALLATION

• Make sure clearance between tail tube and rear bumper is even.
• With engine running, check exhaust tube joints for gas leakage and unusual noises.
• Ensure that mounting brackets and mounting rubbers are installed properly and free from undue stress.
Improper installation could result in excessive noise and vibration.

EX-6
 PRECAUTIONS
< PRECAUTION > [MR20DE]

PRECAUTION A
PRECAUTIONS
Removal and Installation INFOID:0000000000905816
EX
CAUTION:
• Be sure to use genuine exhaust system parts or equivalents which are specially designed for heat
resistance, corrosion resistance, and shape. C
• 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. D

EX-7
 PREPARATION
< PREPARATION > [MR20DE]

PREPARATION
PREPARATION
Special Service Tools INFOID:0000000000905819

Tool number
Description
Tool name
KV10114400 Loosening or tightening heated oxygen sen-
Heated oxygen sensor wrench sor 2
For 22 mm (0.87 in) width hexagon nut

S-NT636

Commercial Service Tools INFOID:0000000000905821

Tool name Description

Heated oxygen sensor thread cleaner Reconditioning the exhaust system threads
before installing a new heated oxygen sensor
(Use with anti-seize lubricant shown below.)
a: 18 mm (0.71 in) dia. for zirconia heated
oxygen sensor
b: 12 mm (0.47 in) dia. for titania heated ox-
ygen sensor
AEM488

Anti-seize lubricant (Permatex 133AR Lubricating heated oxygen sensor thread

or equivalent meeting MIL specifica- cleaner when reconditioning exhaust system
tion MIL-A-907) threads

AEM489

EX-8
 EXHAUST SYSTEM
< ON-VEHICLE MAINTENANCE > [MR20DE]

ON-VEHICLE MAINTENANCE A
EXHAUST SYSTEM
Inspection INFOID:0000000000905823
EX
Check exhaust pipes, muffler and mounting for improper attachment,
leaks, cracks, damage or deterioration.
• If anything is found, repair or replace damaged parts. C

SMA211A

EX-9
 EXHAUST SYSTEM
< ON-VEHICLE REPAIR > [MR20DE]

ON-VEHICLE REPAIR
EXHAUST SYSTEM
Exploded View INFOID:0000000000905825

JPBIA0295GB

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

4. Mounting rubber 5. Spring 6. Seal bearing
7. Exhaust front tube 8. Heated oxygen sensor 2 9. Seal bearing
10. Stud bolt 11. Spring
A. Insulator (4WD models)
Refer to GI-4, "Components" for symbols in the figure.

Removal and Installation INFOID:0000000000905826

REMOVAL
• Disconnect each joint and mounting.
• Remove heated oxygen sensor 2 with following procedure.

EX-10
 EXHAUST SYSTEM
< ON-VEHICLE REPAIR > [MR20DE]
- Using heated oxygen sensor wrench [SST: KV10114400] (A),
removal heated oxygen sensor 2 (1). A
CAUTION:
Be careful not to damage heated oxygen sensor 2.
EX

JPBIA0460ZZ

D
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
• Always replace seal bearings with new ones when reassembling. E
• Discard any heated oxygen sensor 2 which has been dropped onto a hard surface such as a con-
crete floor; use a new one.
• Before installing a new heated oxygen sensor 2, clean exhaust system threads using the heated oxy- F
gen sensor thread cleaner and apply anti-seize lubricant (commercial service tool).
• Never over torque heated oxygen sensor 2. Doing so may cause damage to the heated oxygen sen-
sor 2, resulting in the “MI” coming on.
• Remove deposits from the sealing surface of each connection. Connect them securely to avoid gas G
leakage.
• Temporarily tighten mounting nuts and bolts. Check each part for unusual interference, and then
tighten them to the specified torque. H
• When installing each mounting rubber, avoid twisting or unusual extension in up/down and right/left
directions.
Exhaust Manifold to Exhaust Front Tube I
1. Securely insert seal bearing (2) into exhaust manifold (1) side in
the direction shown in figure.
J
3 : Spring
4 : Mounting nut
5 : Exhaust front tube K
CAUTION:
Be careful not to damage seal bearing surface when install-
ing. L
2. With spring, tighten mounting nut. PBIC3797E
• Be careful that mounting nut does not interfere with flanged
area ( ), and tighten it. M
Exhaust Front Tube to Main Muffler
1. Securely insert seal bearing (2) into exhaust front tube (1) side
in the direction shown in figure. N

3 : Spring
4 : Mounting bolt O
5 : Main muffler
CAUTION:
Be careful not to damage seal bearing surface when install- P
ing.
2. With spring, tighten mounting bolt. PBIC3798E
• Be careful that mounting bolt does not interfere with flanged
area ( ), and tighten it.
Inspection INFOID:0000000000905827

EX-11
 EXHAUST SYSTEM
< ON-VEHICLE REPAIR > [MR20DE]
INSPECTION AFTER INSTALLATION
• Make sure 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.

EX-12
 PRECAUTIONS
< PRECAUTION > [K9K]

PRECAUTION A
PRECAUTIONS
Removal and Installation INFOID:0000000001062578
EX
CAUTION:
• Be sure to use genuine exhaust system parts or equivalents which are specially designed for heat
resistance, corrosion resistance, and shape. C
• 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. D

EX-13
 EXHAUST SYSTEM
< ON-VEHICLE MAINTENANCE > [K9K]

ON-VEHICLE MAINTENANCE
EXHAUST SYSTEM
Inspection INFOID:0000000001062581

Check exhaust pipes, muffler and mounting for improper attachment,

leaks, cracks, damage or deterioration.
• If anything is found, repair or replace damaged parts.

SMA211A

EX-14
 EXHAUST SYSTEM
< ON-VEHICLE REPAIR > [K9K]

ON-VEHICLE REPAIR A
EXHAUST SYSTEM
Exploded View INFOID:0000000001062582
EX

E1BIA0013GB J

1. Seal bearing 2. Spring 3. Exhaust front tube

4. Seal bearing 5. Spring 6. Muffler
K
7. Mounting rubber
A. To catalyst
Refer to GI-4, "Components" for symbols not described on the above. L
Removal and Installation INFOID:0000000001062587

CAUTION: M
• 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 is still hot just N
after the engine stops.
• Be careful not to cut your hand on the insulator edge.
REMOVAL O
• Disconnect each joint and mounting.
INSTALLATION
• Install in the reverse order of removal. P
CAUTION:
• Always replace exhaust 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 insula-
tor, remove them.
• When installing the insulator avoid large gaps or interference between the insulator and each
exhaust pipe.

EX-15
 EXHAUST SYSTEM
< ON-VEHICLE REPAIR > [K9K]
• 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 vehicle
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 INFOID:0000000001062584

INSPECTION AFTER INSTALLATION

• 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.

EX-16