Group:
Bulletin No.:
Issue Date:

TECHNICAL

17-Intake and
Exhaust
SB-15-017
03-06-2015

SERVICE BULLETIN

08MY-10MY J05 Broken Exhaust Manifold Studs
Supersedes SB-11-001 dated 7-21-2011
OVERVIEW
New parts are available to prevent repeat exhaust manifold stud failures on the J05 engine. This bulletin
provides instructions for an exhaust manifold attachment modification at the #1 and #4 cylinder locations.
Modifications to the manifold insulator shield and the turbocharger water return pipe have also been
made to accommodate the longer studs.
NOTE: This procedure is provided as technical information and is not an authorization for a warranty repair.
SUBJECT VEHICLES
Certain 2008MY through 2010MY Hino Conventional 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
17444E0060
SZ91016217
SZ12610009
SZ12610006
SZ12610012
SZ17810007
S171041610
Page 1 of 7

PART DESCRIPTION
Spacer (45 mm)
Spacer (20 mm)
Spacer (8 mm)
Stud (96 mm)
Stud (67 mm)
Stud (56 mm)
Nut (14 mm)
Manifold Gasket

QUANTITY
5
1
6
5
1
6
12
4
Vendor Ref.: HMM-150216-J2

Group:
Bulletin No.:
Issue Date:

TECHNICAL
S241091860
S171042010
S241791430
S241091840
S171041490
SZ46910009
SZ43014003
SL72201210
SL72201415
S241351161
16895E0200
S171416472
S170445501

17-Intake and
Exhaust
SB-15-017
03-06-2015

SERVICE BULLETIN

Turbo Gasket
EGR Cooler Gasket
Intake Pipe Gasket
Exhaust Connector Gasket
Exhaust Pipe Gasket
Clip (Water Return Pipe)
Gasket (Water Pipe inlet/return)
Gasket (Oil inlet)
Gasket (Oil inlet)
Gasket (Oil outlet)
Water Return Pipe
Exhaust Manifold
Exhaust Manifold Insulator

1
2
1
1
1
2
8
2
2
2
As required
As required
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 7

Vendor Ref.: HMM-150216-J2

Group:
Bulletin No.:
Issue Date:

TECHNICAL

17-Intake and
Exhaust
SB-15-017
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 turbocharger, water return pipe, insulator shield, and exhaust manifold from the engine as
outlined within the Engine Workshop Manual. Retain the turbocharger, exhaust manifold, and insulator shield
for reinstallation.
NOTICE: Replacement of the original water pipe depends upon the size of the exhaust manifold stud for the
#1 cylinder.
The original water return pipe MUST BE DISCARDED if the #1 cylinder is equipped with the short (56 mm)
exhaust manifold studs.
Page 3 of 7

Vendor Ref.: HMM-150216-J2

Group:
Bulletin No.:
Issue Date:

TECHNICAL

17-Intake and
Exhaust
SB-15-017
03-06-2015

SERVICE BULLETIN

The original water pipe should be retained for reinstallation if the #1 cylinder is equipped with the long (96
mm) exhaust manifold studs, as shown below.
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 an M10x1.5mm tap.
NOTICE: There are three different lengths of the studs to be installed in the cylinder head. Be sure to install
each stud in the correct location.
3. Install the new studs into the cylinder head as shown in the photograph below. Reference
the table below for the correct stud location. Tighten the studs to the specified torque.
Specified Torque: 22 lb-ft (30 Nm)
NOTICE: Excessive torque on the exhaust manifold studs could cause the cylinder head to
crack.
Stud

Location

Part Number
SZ12610012
SZ12610006
SZ12610009

A
B
C

Length
56 mm
67 mm
96 mm

Stud Locations
C

C

B

#4 cylinder
Page 4 of 7

A

A

A

A

A

A

C

C

C

#1 cylinder
Vendor Ref.: HMM-150216-J2

Group:
Bulletin No.:
Issue Date:

TECHNICAL

17-Intake and
Exhaust
SB-15-017
03-06-2015

SERVICE BULLETIN

4. Check the exhaust manifold for excessive warpage using a calibrated straight edge and
a feeler gauge. When measuring across all 4 exhaust manifold ports, the warpage should
not exceed .009”. If the warpage specification is exceeded, the exhaust manifold MUST
be replaced.
5. Install the exhaust manifold gaskets and exhaust manifold as outlined in the Exhaust
section (EN04) of the Engine Workshop Manual.
NOTICE: There are three 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
C

Page 5 of 7

Spacer
Part Number
SZ91016217
17444E0060
SZ91016297

Length
8 mm
20 mm
45 mm

Vendor Ref.: HMM-150216-J2

Group:
Bulletin No.:
Issue Date:

TECHNICAL

17-Intake and
Exhaust
SB-15-017
03-06-2015

SERVICE BULLETIN

Spacer Locations
C

A

C

A

A

B
#4 cylinder

A

C

A

A

C

C

#2 & #3 cylinder

#1 cylinder

6. The original end of the exhaust manifold insulator shield will not allow proper clearance
to the longer #1 exhaust stud spacers. If the insulator has not already been modified, the
insulator will need to be bent downward to accommodate the longer studs on the #1
cylinder. Bend the corner of the shield downward to provide additional clearance for the
#1 stud and spacer. Install the exhaust manifold insulator shield onto the exhaust
manifold.
NOTICE: Do not cut the shield or bend the shield more than 4 times to prevent strength
reduction. Also do not bend the shield in the opposite direction.
Original

Page 6 of 7

Modified

Vendor Ref.: HMM-150216-J2

Group:
Bulletin No.:
Issue Date:

TECHNICAL
7. Install the water return pipe
(16895E0200) using new sealing washers.

17-Intake and
Exhaust
SB-15-017
03-06-2015

SERVICE BULLETIN

Water Return
Pipe

NOTICE: As set forth in Step 1, the water
return pipe only requires replacement if the
engine was equipped with the short 56 mm
exhaust manifold studs on the #1 cylinder.
NEVER attempt to reuse the water return
pipe if the engine had the short 56 mm
exhaust manifold studs on the #1 cylinder.
8. Install the turbocharger, intake pipes, and exhaust pipe as outlined in 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)

Conventional NA6J, NB6J and NC6J Models: 5.4hrs*
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 7 of 7

Vendor Ref.: HMM-150216-J2