Group:
Bulletin No.:
Issue Date:

TECHNICAL

17-Intake and
Exhaust
SB-15-016
03-06-2015

SERVICE BULLETIN

13MY-15MY COE J05 Broken Exhaust Manifold Studs
OVERVIEW
New parts are available to prevent repeat exhaust manifold stud failures on the J05 engine. This bulletin provides
instructions for installing longer manifold studs at the #4 cylinder location.
NOTE: This procedure is provided as technical information and is not an authorization for a warranty repair.
SUBJECT VEHICLES
Certain 2013MY through 2015MY Hino COE vehicles equipped with a J05 engine.
BEFORE YOU BEGIN:









Read and understand all instructions and procedures before you begin the work.
Read and follow all WARNINGS and NOTICES set forth in this publication. These alerts help to avoid
damage to components, serious personal injury, or both.
Park the vehicle on a level and solid surface and apply the parking brake.
Place the gear shift lever in "Neutral" or “N”.
Confirm the engine is stopped, the ignition switch is in the off (LOCK) position, and the key is removed.
Wear safety glasses to prevent eye injuries.
Place wheel chocks in front of and behind all the wheels to prevent the vehicle from moving.
Wait until the engine and exhaust are cool enough to touch before servicing the exhaust studs.

PARTS
PART NUMBER
SZ91016297
SZ91016217
SZ12610009
SZ12610012
SZ17810007
S171041610
S241091860
S171042010
S241791430
S241091860
17451E0110
Page 1 of 6

PART DESCRIPTION
Spacer (45 mm)
Spacer (8 mm)
Stud (96 mm)
Stud (56 mm)
Nut (14 mm)
Manifold Gasket
Turbo Gasket
EGR Cooler Gasket
Intake Pipe Gasket
Exhaust Connector Gasket
Exhaust Pipe Gasket

QUANTITY
6
6
6
6
12
4
1
2
1
1
1
Vendor Ref.: HMM-150216-J1

Group:
Bulletin No.:
Issue Date:

TECHNICAL
SZ46910009
SZ43014003
SL72201210
SL72201415
S241351161
17141E0260

17-Intake and
Exhaust
SB-15-016
03-06-2015

SERVICE BULLETIN

Clip (Water Return Pipe)
Gasket (Water Pipe inlet/return)
Gasket (Oil inlet)
Gasket (Oil inlet)
Gasket (Oil outlet)
Exhaust Manifold

2
8
2
2
2
As required

VEHICLE PREPARATION:
1. Park the vehicle on level and solid
surface.

2. Confirm the engine is stopped, the
ignition switch in the off (LOCK) position
and the key is removed.

Page 2 of 6

Vendor Ref.: HMM-150216-J1

Group:
Bulletin No.:
Issue Date:

TECHNICAL

17-Intake and
Exhaust
SB-15-016
03-06-2015

SERVICE BULLETIN

3. Apply the parking brake.

4. Chock the front wheels.

REPAIR PROCEDURE:
WARNING: Touching a hot exhaust may result in burns or serious injuries. Do not touch the exhaust when hot.
1. Allow the engine to cool to the point where the exhaust is cool to the touch. Remove
the exhaust manifold as outlined by section 11-3 of the Engine Workshop Manual.
Retain the exhaust manifold for reinstallation.
2. First remove and discard any broken exhaust manifold studs from the cylinder head.
Then, remove and discard all remaining exhaust manifold studs from the cylinder head.
Clean the threads of the exhaust stud bores using a M10x1.5mm tap.
NOTICE: There are two different lengths of the studs to be installed in the cylinder
head. Be sure to install each stud in the correct location.

Page 3 of 6

Vendor Ref.: HMM-150216-J1

Group:
Bulletin No.:
Issue Date:

TECHNICAL

17-Intake and
Exhaust
SB-15-016
03-06-2015

SERVICE BULLETIN

3. Install the new studs into the cylinder head as shown in the photograph below,
referencing the table below for proper stud location. Tighten the studs to the specified
torque..
Specified Torque: 22 lb-ft (30Nm)
NOTICE: Excessive torque on the exhaust manifold studs could cause the cylinder head
to crack.
Location
A
B

Stud
Part Number
SZ12610012
SZ12610009

Length
56 mm
96 mm

4. Check the exhaust manifold for excessive warpage using a calibrated straight edge
and a feeler gauge. Across all 4 exhaust manifold ports, warpage should not exceed
.009”. If the warpage specification is exceeded, the exhaust manifold MUST be replaced.

Page 4 of 6

Vendor Ref.: HMM-150216-J1

Group:
Bulletin No.:
Issue Date:

TECHNICAL

17-Intake and
Exhaust
SB-15-016
03-06-2015

SERVICE BULLETIN

5. Install the exhaust manifold gaskets and exhaust manifold as outlined in the Exhaust
section (11-7) of the Engine Workshop Manual.
NOTICE: There are two different lengths of the spacers to be installed. Be sure to install
each spacer in the correct location.
Install the spacers as shown in the illustration below. Refer to the table below for the part
number of each spacer. Install the 14mm nut (SZ17810007) onto each of the studs, and
tighten the nuts to the specified torque following the torque sequence outlined in the
workshop manual. Once all 12 nuts have been torqued to specification, re-torque them
again in the same sequence.
Specified Torque: 43.5 lb-ft (59 Nm)
NOTICE: Make sure that the spacer remains centered while tightening the nut.
NOTICE: There is a different torque sequence for a new exhaust manifold compared to a
previously used exhaust manifold. Be certain to reference the Workshop Manual for the
proper torque sequence.
Location
A
B

Spacer
Part Number
SZ91016217
SZ91016297

Spacer Locations
B
B

B
#4 cylinder

Page 5 of 6

Length
8 mm
45 mm

A

A

A

A

A

A
#2 & #3 cylinder

B

B

B
#1 cylinder

Vendor Ref.: HMM-150216-J1

Group:
Bulletin No.:
Issue Date:

TECHNICAL

17-Intake and
Exhaust
SB-15-016
03-06-2015

SERVICE BULLETIN

6. Install the turbocharger, intake pipes, and exhaust pipe as outlined by the Engine Workshop Manual.
FINAL INSPECTION:
1. To complete this technical service bulletin, review the bulletin and confirm the following:




All nuts and bolts have been tightened to their specified torque
There are no exhaust leaks present

NOTE: This repair may be eligible for reimbursement if a product failure was experienced within the time and
mileage limits of the applicable warranty coverage. Reimbursement is obtained via normal claim handling
process.
Claim Application:
* Reimbursable in accordance within the terms and policies of the Hino Truck limited warranties.
a)
b)
c)
d)
e)

Labor Charge: 3.0 Hrs*
Warranty Code: 05211
Trouble Code 50
Operation Code: 05201BRE
Part Number: 9999999

*If additional labor time is needed to drill out or extract broken exhaust studs, use operation code 05250AOT to
reflect actual work time.

Page 6 of 6

Vendor Ref.: HMM-150216-J1