HKS Super Turbo Muffler Ti Installation and User Manual

Foreword

Thank you for purchasing the HKS exhaust system. Please read this User & Installation Manual thoroughly before using this product to ensure correct understanding and usage. Confirm that the contents are correct before installation on the vehicle.

Important Notes:

• Do not perform any illegal modifications on this product, such as cutting the pipe or removing internal muffler components.
• HKS shall not bear any responsibility for product breakdown or damage caused by modification, disassembly, misuse, or third-party actions.
• Product specifications and parts may be revised without prior notice.
• It is illegal to drive a vehicle with the catalytic converter or other emission devices removed or modified, unless specified by local regulations.

Product Precautions

When the engine is on or immediately after it stops, the exhaust manifold, exhaust pipe, catalyst, and muffler are extremely hot. Be careful not to touch these parts, as you may suffer burns. Clothing could burn or melt if it touches the tailpipe when loading/unloading items from the trunk. Take caution around the vehicle when stopping or parking.

• Oil or brake fluid spilled on the exhaust manifold could ignite.
• Exhaust gases contain toxic substances. There is a danger of carbon monoxide poisoning if you work in a poorly ventilated area with the engine running. Always turn off the engine and ensure adequate ventilation. Be especially careful if pets or children are nearby. Note wind direction when running the vehicle near people.
• This aftermarket exhaust improves exhaust efficiency and performance. Ensure brakes are fully serviced and check all undercarriage components for safety.
• The system is designed for standard vehicle height. If the vehicle is lowered significantly, the muffler could be damaged or damage other objects. Do not lower the vehicle to extreme levels, as this could cause exhaust gas leaks.
• Even with correct usage, sound muffling performance may deteriorate due to exhaust gases or corrosion, potentially causing holes. Consult your dealer if the product loses its original capabilities. Corrosion can lead to fire from exhaust gas leaks and may result in fines for driving a poorly maintained vehicle.
• It is the driver's legal responsibility to maintain their car safely. Periodic inspections and service are essential for safety and pollution prevention.

Installation Precautions

Follow all instructions precisely. Use a torque wrench for proper screw tightening to prevent loosening during operation.

• Exhaust manifolds and catalytic converters get extremely hot. Contact may cause severe burns. Work only after the system has cooled down. Use heat-resistant gloves.
• Rust may make nuts and bolts difficult to loosen. Use penetrating lubricant and appropriate tools. Avoid excessive force that could break parts. Always use heat-resistant gloves to protect your hands.
• Exhaust system replacement is typically done underneath the vehicle. Ensure the lifted vehicle is stable. Use a specified lifting machine; never rely solely on a standard car jack. Working alone can be dangerous due to simultaneous tightening and supporting heavy parts; always work with two or more people.
• Maintain proper clearance, especially near brakes, fuel lines, drivetrain, and electrical systems.
• Replace any worn or cracked rubber exhaust hangers with new manufacturer parts.
• After removing the stock exhaust, disassemble it into the shortest possible pieces and store horizontally for moisture dissipation. It may be necessary to cut the stock exhaust into two pieces for removal.
• The HKS exhaust system is designed for direct bolt-on installation without vehicle or system modification.
• Stock bolts removed during bracket installation should not be reused; keep them with the stock muffler.

Parts List / Hardware

Required Tools:

• 12mm Open-end Wrench
• 14mm Open-end Wrench

Diagram Descriptions

Exploded View of Exhaust System Components

This diagram illustrates the assembly of the HKS Super Turbo Muffler Ti. It shows the Mid Pipe connecting to the Main Muffler via a Ring Gasket. Various bolts, nuts, washers (including spring and flat washers), and rubber stays are used to secure these components and attach them to the vehicle's chassis. The diagram also indicates the connection points for the stock exhaust system components, such as the stock bolts, spherical gasket, spring, rubber stay, and flange nut.

Bracket Installation Diagram

This diagram shows the bracket installation process. It details how a spacer is placed between the vehicle's bracket attachment point and the HKS bracket. A bolt (M8 P=1.25 L=35), spring washer (M8), and flat washer (M8) are used to temporarily assemble these parts. The diagram emphasizes adjusting the bracket for a 2-3mm clearance between the bracket and the rubber component.

Clearance Check Diagram

This diagram illustrates the clearance check between the tailpipe and the vehicle's bumper. It indicates approximate measurements: about 20mm for the upper clearance and about 28mm for the inside clearance. The diagram notes that clearance should be checked for both left and right sides and that insufficient clearance may lead to abnormal noise or bumper melting due to heat.

Compatible Vehicles and Product Specifications

• Vehicle: TOYOTA GR YARIS
• Vehicle Model: 4BA-GXPA16
• Model Year: 2024/4~
• Compatibility Information Date: July 2, 2025 (as of this printing). For the latest compatibility information, please visit: http://www.hks-power.co.jp/product/exhaust/index.html
• Engine Model: G16E-GTS
• Product Name: Super Turbo Muffler Ti
• Product Number: 31030-AT002
• Performance Confirmation Mark: JQR30252055 G16Et. Information is available online at https://www.jqr.jp/

Vehicle Clearance After Installation:

• Minimum Ground Clearance (under front member): Approximately 120 mm
• Minimum Ground Clearance (under mid pipe): Approximately 135 mm

Note: There is no change in minimum ground clearance due to the installation of this product.

Installation Procedure

Please request a specialized maintenance shop for installation. The term "stock part" refers to the standard equipment provided by the car manufacturer.

Preparation:

• Before starting work, confirm the vehicle and product compatibility using the vehicle inspection certificate and this manual.
• Remove stock parts (muffler) according to the manufacturer's work instructions.

Assembly Steps:

1. Temporary Assembly of Mid Pipe:
   • Align the mid pipe in its correct position and attach the stock rubber stay to the hanging hooks.
   • Insert the supplied stock spherical gasket between the rear flange of the stock catalyst and the front flange of the mid pipe. Insert the stock spring into the stock bolt, pass it through from the front, and then tentatively fit the supplied flange nut from the opposite side.
2. Temporary Assembly of Main Muffler:
   • Align the main muffler in its correct position and attach the provided rubber stays (2 pcs) to the hanging hooks on the main muffler. Align the mid pipe correctly and insert the stock rubber stay into its hooks.
   • Insert the supplied ring gasket (D75) between the rear flange of the mid pipe and the front flange of the main muffler. Insert a flat washer (M10) onto the supplied bolt (M10 P=1.5 L=25), pass it through from the front, and then tentatively fit the supplied flat washer (M10), spring washer (M10), and nut (M10 P=1.5) from the opposite side.
3. Assemble the Entire System:
   • Check the positional relationship of each pipe and muffler, clearances with the floor, cross member, and other parts. Ensure proper alignment of gaskets between flanges.
   • Tighten the temporarily fitted bolts and nuts in order from the front of the car to the specified torque.

   Tightening Torques:

   M10 Bolts	29 ~ 34 N·m (3.0 ~ 3.5 kgf·m)
   Stock Bolt (M10)	43 N·m (4.4 kgf·m)

   Note: The ring gasket cannot be reused as it will deform when tightened to the specified torque.

4. Clearance Check (Tailpipe to Bumper):
   • Check the alignment and clearance between the tailpipe and the bumper. Target clearance is approximately 20 mm (upper) and 28 mm (inside). Retighten if any defects are found. Insufficient clearance may cause abnormal noise or melt the bumper by heat. Check both left and right sides.
5. Verifying Correct Installation:
   • After installation, shake the muffler to check clearances for each section.
   • Start the engine, let it idle, and rev to approximately 2,500 rpm. Check for exhaust leaks and abnormal sounds from the flanges.
   • Drive the vehicle for a while and re-check for exhaust leaks and abnormal sounds from the flanges.
   • If any issues are found in steps (1) through (3), reinstall the product from the beginning.
6. Installation of the Bracket:
   • Remove the two stock bolts from the inner side of the vehicle's rear left. (Note: The photo shows the muffler removed for convenience; work with the muffler attached.) The removed bolts will not be reused, so store them safely.
   • Temporarily assemble the bracket using the spacer, bolt (M8 P=1.25 L=35), spring washer (M8), and flat washer (M8) between the bracket and the vehicle's attachment point.
   • Adjust the bracket position to achieve a clearance of 2 to 3 mm between the bracket and the rubber. Tighten the bolt to the specified torque.

   Tightening Torque:

   M8 Bolt

   17 N·m (1.7 kgf·m)

   ℹ️ Note: Bracket Clearance

   If the bracket and rubber contact each other while driving, vibrations or abnormal sounds may occur in the car. Ensure the specified clearance is maintained.

Company Information

HKS Co., Ltd.

7181 Kitayama, Fujinomiya, Shizuoka 418-0192, JAPAN

Website: https://www.hks-power.co.jp/en/