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

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

Lubricating heated oxygen sensor thread
cleaner when reconditioning exhaust system
threads

AEM488

AEM489

EXHAUST SYSTEM

EX-5

< PERIODIC MAINTENANCE >

[HRA2DDT]

PERIODIC MAINTENANCE

EXHAUST SYSTEM

Inspection

INFOID:0000000010287087

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-6

< REMOVAL AND INSTALLATION >

[HRA2DDT]

EXHAUST SYSTEM

REMOVAL AND INSTALLATION

EXHAUST SYSTEM

Exploded View

INFOID:0000000010287088

Refer to

GI-4, "Components"

for symbol marks in the figure.

Removal and Installation

INFOID:0000000010287089

REMOVAL

Remove main muffler.

Remove center tube.

Remove front tube.

INSTALLATION

Note the following, and install in the reverse order of removal.

CAUTION:

• Always replace exhaust gaskets with new ones when reassembling.

Gasket

Mounting rubber

Exhaust front tube

Center muffler

Main muffler

E1BIA1125GB

EXHAUST SYSTEM

EX-7

< REMOVAL AND INSTALLATION >

[HRA2DDT]

• 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 avoir large gaps or interference between the insulator and each

exhaust pipe.

• Remove desits from the sealing surface or each connection. Connect them securely to avoid gas

leakage.

• If it is difficult to install mounting rubber, use mild detergent for smooth installation.
• When installing each mounting rubber, avoid twisting or unusual extension in up/down and right/left

directions.

• Temporarily tighten mounting nuts. Check each part for unusual interference, and then tighten them

to the specified torque.

Inspection

INFOID:0000000010287090

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-8

< PRECAUTION >

[MR20DD]

PRECAUTIONS

PRECAUTION

PRECAUTIONS

Removal and Installation

INFOID:0000000010665049

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.
• Never use silicon-containing products (e.g. oil) to prevent malfunctions such as the interference with

the conduction of electricity and the occurrence of noise in the radio.

• Prevent rust preventives from adhering to the sensor body.

Precautions for Removing Battery Terminal

INFOID:0000000010665050

• 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
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.

SEF289H

PREPARATION

EX-9

< PREPARATION >

[MR20DD]

PREPARATION

Special Service Tools

INFOID:0000000010665051

Commercial Service Tools

INFOID:0000000010665052

Tool number
Tool name

Description

KV10114400
Heated oxygen sensor wrench

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

S-NT636

Tool name

Description

Power tool

Loosening nuts and bolts

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: J-43897-18 [18 mm (0.71 in) dia.] for zir-
conia heated oxygen sensor
B: J-43897-12 [12 mm (0.47 in) dia.] for tita-
nia heated oxygen sensor
C: Mating surface shave cylinder
D: Flutes

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

Lubricating heated oxygen sensor thread
cleaner when reconditioning exhaust system
threads

PBIC0190E

JPBIA0238ZZ

AEM489

EX-10

< PERIODIC MAINTENANCE >

[MR20DD]

EXHAUST SYSTEM

PERIODIC MAINTENANCE

EXHAUST SYSTEM

Inspection

INFOID:0000000010665053

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

EXHAUST SYSTEM

EX-11

< REMOVAL AND INSTALLATION >

[MR20DD]

REMOVAL AND INSTALLATION

EXHAUST SYSTEM

Exploded View

INFOID:0000000010665054

Removal and Installation

INFOID:0000000010665055

REMOVAL

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

Gasket

Exhaust front tube

Heat insulator

Heat insulator (If equipped)

Heated oxygen sensor 2

Mounting rubber

Gasket

Mounting rubber

Main muffler

Mounting rubber

To exhaust manifold

: Always replace after every disassembly.

: N·m (kg-m, in-lb)

: N·m (kg-m, ft-lb)

E1BIA1179GB

- 1

< REMOVAL AND INSTALLATION >

[MR20DD]

EXHAUST SYSTEM

- Using heated oxygen sensor wrench [SST: KV10114400] (A),

removal heated oxygen sensor 2

CAUTION:

Discard any sensor which has been dropped from a height of
more than 0.5 m (19.7 in) onto a hard surface such as a con-
crete floor; use a new one.

INSTALLATION

Note the following, and install in the reverse order of removal.

CAUTION:

• Always replace gaskets 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 [commercial service tool (J-43897-18 or J-43897-12)] 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 “MIL” coming on.

• If heat insulator is badly deformed, repair or replace it. If deposits such as mud pile up on the heat

insulator, remove them.

• When installing heat insulator avoid large gaps or interference between heat 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 and bolts. Check each part for unusual interference and mount-

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.

• Install mounting rubber, refer to the following instructions,
- Install slit of the mounting rubber

is in a horizontal direction.

Inspection

INFOID:0000000010665056

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.

: Exhaust front tube

: Vehicle front

JSBIA4404ZZ

: RH

: LH

: Vehicle upper

JPBIA6874ZZ

PRECAUTIONS

EX-13

< PRECAUTION >

[K9K]

PRECAUTION

PRECAUTIONS

Removal and Installation

INFOID:0000000010427903

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.

• Never cut your hand on the heat insulator edge.

EX-14

< PERIODIC MAINTENANCE >

[K9K]

EXHAUST SYSTEM

PERIODIC MAINTENANCE

EXHAUST SYSTEM

Inspection

INFOID:0000000010427904

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

SMA211A

EXHAUST SYSTEM

EX-15

< REMOVAL AND INSTALLATION >

[K9K]

REMOVAL AND INSTALLATION

EXHAUST SYSTEM

Exploded View

INFOID:0000000010427905

Refer to

GI-4, "Components"

for symbols in the figure.

Removal and Installation

INFOID:0000000010427906

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 is still hot just

after the engine stops.

• Never cut your hand on the insulator edge.

REMOVAL

Remove main muffler.

Remove center tube.

Gasket

Mounting rubber

Exhaust front tube

Exhaust shutter

Exhaust center tube

Main muffler

E1BIA1126GB

EX-16

< REMOVAL AND INSTALLATION >

[K9K]

EXHAUST SYSTEM

Disconnect exhaust throttle valve connector.

Unclip and move aside exhaust throttle valve harness.

Remove front tube.

INSTALLATION

Note the following, and install in the reverse order of removal.

Exhaust Front Tube and Main Muffler

When replacing the Exhaust electric throttle control actuator, this procedure must be performed. Refer to

ECK-130, "Special Repair Requirement List"

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.

• Remove deposits from the sealing surface of each connection. Connect them securely to avoid gas

leakage.

• If it is difficult to install mounting rubber, use mild detergent for smooth installation.
• When installing each mounting rubber, avoid twisting or unusual extension in up/down and right/left

directions.

• Temporarily tighten mounting nuts. Check each part for unusual interference, and then tighten them

to the specified torque.

Inspection

INFOID:0000000010427907

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.

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