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EXHAUST
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15-1
INTAKE AND
EXHAUST
CONTENTS
SERVICE SPECIFICATION . . . . . . . . . . . . . . . . . . 2
EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . . 6
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CATALYTIC CONVERTER
. . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . 4
15-2
SERVICE SPECIFICATION
Items
Standard value
Limit
0.15 or less
0.20
SPECIAL TOOL
Tool
Number
Name
Use
MD998770
Oxygen sensor
wrench
15-3
AIR CLEANER
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Engine Cover Removal and Installation
10 Nm
8
1
5
9
9 Nm
10
2
4
6
7
15-4
INTAKE MANIFOLD
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Engine Coolant Draining and Supplying
(Refer to GROUP 14 On-vehicle Service.)
D Engine Cover and Under Cover Removal and
Installation
D Resonance Tank Removal and Installation
(Refer to P.15-3.)
D
D
20 Nm
16
20
24 Nm
21
17
18
19 Nm
19
9 Nm
10 12 Nm
10
11
5
8
11
10 12 Nm
12
10 12 Nm
10 12 Nm 6
28 Nm
13
4
27 34 Nm
34 Nm
14
15
Removal steps
1. Engine coolant temperature sensor
connector connection
2. Condenser connector connection
3. Camshaft position sensor connector
connection
4. Injector harness connector connection
5. Purge control solenoid connector
connection
6. EGR valve connector connection
7. Harness connector bracket
8. Water hose and pipe
9. Brake booster vacuum hose
AA"
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
34 Nm
15-5
INSPECTION
Check the following points; replace the part if a problem is
found.
INTAKE MANIFOLD CHECK
1. Check for damage or cracking of any part.
2. Using a straight edge and thickness gauge, check for
distortion of the cylinder head installation surface.
Standard value: 0.15 mm or less
Limit: 0.20 mm
15-6
EXHAUST MANIFOLD
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Engine Cover and Under Cover Removal and
Installation
5
8
18 Nm
29 Nm
13 Nm
2
29 Nm
98 Nm
12 15
Nm
13 Nm
34 Nm
34 Nm
1
Removal steps
1. Front exhaust pipe connection
2. Exhaust manifold bracket
3. Engine oil level gauge guide
4. Washer tank filler tube
5. A/C pressure switch connector
connection
15-7
13 Nm
1
4
13 Nm
12
34 Nm
49 Nm
7
13 Nm
11
34 Nm
34 Nm
49 Nm
10
9
13
14
A
MD998770
NOTES
15-1
GROUP 15
A
Removal step
1. Oxygen sensor (rear)
15-1
GROUP 15
SERVICE SPECIFICATION
Items
Standard value
Limit
0.15 or less
0.20
AIR CLEANER
REMOVAL AND INSTALLATION
<4G9-MPI>
11
12 2 Nm
3.9 1.0 Nm
4.0 1.0 Nm
5
6
8.8 1.0 Nm
7
12
13
3.9 1.0 Nm
4
9.0 1.0 Nm
9
10
Removal steps
1. Air intake hose and resonator
2. Air intake hose
3. Resonator
4. Air flow sensor connector
5. Air flow sensor and air cleaner cover
6. Air flow sensor
7. Air cleaner cover
8.
9.
10.
11.
12.
13.
15-2
INTAKE MANIFOLD
REMOVAL AND INSTALLATION
<4G9-MPI>
Pre-removal and Post-installation Operation
D Engine Coolant Draining and Supplying
D Under Cover Removal and Installation
D Air Cleaner Removal and Installation
(Refer to P.15-2.)
7
6
12 1 Nm
1
2
10
12
9.0 1.0 Nm
11
22
22 4 Nm
23
15
13
14
24
9.0 1.0 Nm
20 2 Nm
Delivery pipe
16
18
20 2 Nm
31 3 Nm
21 20
5.0 1.0 Nm
17
24 1 Nm
19
O-ring
10
Engine oil
5.0 1.0 Nm
Removal steps
1. Noise condenser connector
2. Purge control solenoid valve
connector
3. EGR solenoid valve connector
4. Crank angle sensor connector
5. Detonation sensor connector
6. Injector connector
7. Control harness clamp
8. Intake manifold vacuum hose
connection
9. Brake booster vacuum hose
connection
"AA 10. Fuel pressure hose
11. Return hose
AB"
15-3
O-ring
High-pressure fuel hose
INSPECTION
Check the following points; replace the part if a problem is
found.
INTAKE MANIFOLD CHECK
1. Check for damage or cracking of any part.
2. Check for obstruction of the negative pressure (vacuum)
outlet port, and for obstruction of the water passage or
gas passage.
3. Using a straight edge and thickness gauge, check for
distortion of the cylinder head installation surface.
Standard value: 0.15 mm or less
Limit: 0.20 mm
15-4
EXHAUST MANIFOLD
REMOVAL AND INSTALLATION
<4G9-MPI>
Pre-removal and Post-installation Operation
D Under Cover Removal and Installation
D Air Cleaner Removal and Installation
(Refer to P.15-2.)
13 1 Nm
7
5
18 2 Nm
29 3 Nm
29 3 Nm
13 1 Nm
35 5 Nm
6
4
2
14 1 Nm
35 6 Nm
Removal steps
1. Front exhaust pipe connection
2. Exhaust manifold bracket
3. Engine oil level gauge guide
4. Washer tank filler tube
1
35 5 Nm
15-5
<4G9-MPI>
13 2 Nm
3
50 10 Nm
3. Heat protector
4. Hanger
NOTES