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    GR00002000 15 PDF

    Uploaded by

    Nicu Pascaluta
    This document provides information on intake and exhaust components for a vehicle. It includes: 1) General information on service specifications and special tools for the intake and exhaust system. 2) Procedures for removing and installing the air cleaner, intake manifold, exhaust manifold, and exhaust pipe/main muffler. 3) Inspection instructions for the intake manifold and exhaust manifold to check for damage or distortion.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    GR00002000 15 PDF

    Uploaded by

    Nicu Pascaluta
    76 views12 pages
    This document provides information on intake and exhaust components for a vehicle. It includes: 1) General information on service specifications and special tools for the intake and exhaust system. 2) Procedures for removing and installing the air cleaner, intake manifold, exhaust manifold, and exhaust pipe/main muffler. 3) Inspection instructions for the intake manifold and exhaust manifold to check for damage or distortion.

    Original Title

    GR00002000-15.pdf

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    © © All Rights Reserved

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    This document provides information on intake and exhaust components for a vehicle. It includes: 1) General information on service specifications and special tools for the intake and exhaust system. 2) Procedures for removing and installing the air cleaner, intake manifold, exhaust manifold, and exhaust pipe/main muffler. 3) Inspection instructions for the intake manifold and exhaust manifold to check for damage or distortion.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    76 views12 pages

    GR00002000 15 PDF

    Uploaded by

    Nicu Pascaluta
    This document provides information on intake and exhaust components for a vehicle. It includes: 1) General information on service specifications and special tools for the intake and exhaust system. 2) Procedures for removing and installing the air cleaner, intake manifold, exhaust manifold, and exhaust pipe/main muffler. 3) Inspection instructions for the intake manifold and exhaust manifold to check for damage or distortion.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 12

    15-1

    GROUP 15

    INTAKE AND
    EXHAUST
    CONTENTS
    GENERAL INFORMATION . . . . . . . .
    SERVICE SPECIFICATION . . . . . . . .

    15-2

    15-2

    AIR CLEANER . . . . . . . . . . . . . . . . . .

    15-2

    INTAKE MANIFOLD . . . . . . . . . . . . .
    REMOVAL AND INSTALLATION <4G1> . .

    15-6

    INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

    15-7

    EXHAUST MANIFOLD . . . . . . . . . . . .

    15-8

    REMOVAL AND INSTALLATION <4G1> . .

    15-8

    15-2

    SPECIAL TOOL . . . . . . . . . . . . . . . . .

    REMOVAL AND INSTALLATION . . . . . . . .

    REMOVAL AND INSTALLATION <4G6> . .

    REMOVAL AND INSTALLATION <4G6> . .

    15-9

    INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

    15-10

    15-5

    EXHAUST PIPE AND MAIN


    MUFFLER . . . . . . . . . . . . . . . . . . . . . .

    15-11

    15-5

    REMOVAL AND INSTALLATION . . . . . . . .

    15-11

    15-2

    INTAKE AND EXHAUST

    15-2

    GENERAL INFORMATION

    GENERAL INFORMATION
    M1151000100402

    The exhaust pipe is divided into three parts.

    SERVICE SPECIFICATION
    M1151000300428

    Item

    Standard value

    Limit

    Manifold distortion of the installation surface mm

    0.15 or less

    0.20

    SPECIAL TOOL
    M1151000600399

    Tool

    Number

    Name

    Use

    MD998770

    Oxygen sensor wrench

    Removal and installation of


    engine control oxygen sensor

    AIR CLEANER
    REMOVAL AND INSTALLATION
    M1151002100486

    CAUTION

    Parts marked by * are made of recycled-paper mixed plastic material, so observe the following
    precautions.
    Avoid any shock or load to these parts when removing and installing them.
    When installing, securely set the air cleaner cover clamp to the air cleaner body.
    NOTE: Parts marked by * are made of recycled-paper mixed plastic material. Dispose of according to state
    and local laws.

    INTAKE AND EXHAUST

    15-3

    AIR CLEANER

    <4G1>

    4.0 1.0 Nm

    5
    3*
    10*

    9*

    8*
    4.0 1.0 Nm

    9.0 1.0 Nm

    1*

    Clamp

    12 1 Nm

    9.0 1.0 Nm

    12 1 Nm

    11

    AC303618 AB

    <4G6>

    4
    5
    4.0 1.0 Nm

    3*
    10*

    9.0 1.0 Nm

    9*

    8*

    7 6

    4.0 1.0 Nm

    1*
    8.8 1.0 Nm

    Clamp

    12 1 Nm

    9.0 1.0 Nm

    11

    12 1 Nm
    AC303619 AB

    15-4

    INTAKE AND EXHAUST


    AIR CLEANER
    Removal steps
    1. Air cleaner intake duct
    2. Air cleaner air flow sensor connector
    <4G6>
    3. Air cleaner assembly <4G1> or Air
    cleaner and air cleaner air flow sensor
    assembly <4G6>
    4. Rocker cover breather hose
    connection
    5. Air cleaner to throttle body duct

    Removal steps (Continued)


    6. Air cleaner air flow sensor <4G6>
    7. Air cleaner air flow sensor gasket
    <4G6>
    8. Air cleaner cover
    9. Air cleaner element
    10. Air cleaner body assembly
    11. Air cleaner bracket

    INTAKE AND EXHAUST

    15-5

    INTAKE MANIFOLD

    INTAKE MANIFOLD
    REMOVAL AND INSTALLATION <4G1>
    M1151003000749

    Pre-removal Operation
    Fuel Line Pressure Reduction (Refer to GROUP 13A On-vehicle Service P.13A-387).
    Engine Coolant Draining (Refer to GROUP 14 On-vehicle Service P.14-22).
    Strut Tower Bar Removal (Refer to GROUP 42 P.42-9).
    Throttle Body Assembly Removal (Refer to GROUP 13A
    P.13A-398).
    Fuel Delivery Pipe and Fuel Injector Assembly Removal
    (Refer to GROUP 13A P.13A-396).

    Post-installation Operation
    Fuel Delivery Pipe and Fuel Injector Assembly Installation
    (Refer to GROUP 13A P.13A-396).
    Throttle Body Assembly Installation (Refer to GROUP
    13A P.13A-398).
    Strut Tower Bar Installation (Refer to GROUP 42 P.42-9).
    Engine Coolant Supplying (Refer to GROUP 14 On-vehicle Service P.14-22).
    Accelerator Cable Adjustment (Refer to GROUP 17 On-vehicle Service P.17-2).
    Fuel Leak Check

    21 4 Nm

    9.0 1.0 Nm

    13

    7
    N 14

    11

    N2

    5.0 1.0 Nm

    8
    15

    18 2 Nm

    10
    9.0 1.0 Nm

    12 N
    18 2 Nm

    3
    6
    5

    18 2 Nm

    31 3 Nm
    49 9 Nm

    4
    AC303642 AB

    1.
    2.
    3.
    4.
    5.

    Removal steps
    Inlet manifold absolute pressure
    sensor
    Engine control pressure sensor
    O-ring
    Engine control detonation sensor
    connector
    T/M housing front lower cover stay
    (L.H.)
    Battery wiring harness clamp
    connection

    Removal steps (Continued)


    6. Inlet manifold stay
    7. Brake booster vacuum hose
    connection
    8. Emission control equip hose
    connection
    9. Fuel vapour control hose
    connection
    10. Inlet manifold stay
    11. Inlet manifold
    12. Inlet manifold gasket

    INTAKE AND EXHAUST

    15-6

    INTAKE MANIFOLD
    Removal steps (Continued)
    13. EGR valve
    14. EGR valve gasket

    Removal steps (Continued)


    15. Emission vacuum hose & pipe and
    emission solenoid valve assembly

    REMOVAL AND INSTALLATION <4G6>


    M1151003000772

    Pre-removal Operation
    Fuel Line Pressure Reduction (Refer to GROUP 13A On-vehicle Service P.13A-387).
    Engine Coolant Draining (Refer to GROUP 14 On-vehicle Service P.14-22).
    Strut Tower Bar Removal (Refer to GROUP 42 P.42-9).
    Throttle Body Assembly Removal (Refer to GROUP 13B
    P.13B-340).
    Fuel Delivery Pipe and Fuel Injector Assembly Removal
    (Refer to GROUP 13B P.13B-338).

    Post-installation Operation
    Fuel Delivery Pipe and Fuel Injector Assembly Installation
    (Refer to GROUP 13B P.13B-338).
    Throttle Body Assembly Installation (Refer to GROUP
    13B P.13B-340).
    Strut Tower Bar Installation (Refer to GROUP 42 P.42-9).
    Engine Coolant Supplying (Refer to GROUP 14 On-vehicle Service P.14-22).
    Accelerator Cable Adjustment (Refer to GROUP 17 On-vehicle Service P.17-2).
    Fuel Leak Check

    11 1 Nm

    12
    7

    5.0 1.0 Nm

    2
    20 2 Nm

    9.0 1.0 Nm

    36 6 Nm

    11 1 Nm
    20 2 Nm

    36 6 Nm

    13
    14 N

    36 6 Nm

    11 N

    13 1 Nm

    20 2 Nm

    N6

    10

    (Engine oil)

    9
    31 3 Nm

    AC303657AB

    INTAKE AND EXHAUST

    15-7

    INTAKE MANIFOLD

    1.
    2.
    3.
    4.
    5.
    6.

    Removal steps
    Emission control equip hose
    connector
    Brake booster vacuum hose
    connection
    Earth cable connection
    Engine control detonation sensor
    connector
    Engine oil level gauge and guide
    assembly
    Engine oil filler O-ring

    INSPECTION
    M1151003100616

    Check the following points; replace the part if a


    problem is found.
    Inlet Manifold Check
    1. Check for damage or cracking of any part.

    Removal steps (Continued)


    Emission vacuum hose connection
    Battery wiring harness clamp
    Inlet manifold stay
    Inlet manifold
    Inlet manifold gasket
    Emission vacuum hose & pipe and
    emission solenoid valve assembly
    13. EGR valve
    14. EGR valve gasket
    7.
    8.
    9.
    10.
    11.
    12.

    2. Clogging of the negative pressure (vacuum) outlet


    port, or clogging of the exhaust gas recirculation
    passages.
    3. Using a straight edge and feeler gauge, check for
    distortion of the cylinder head installation surface.
    Standard value: 0.15 mm or less
    Limit: 0.20 mm

    INTAKE AND EXHAUST

    15-8

    EXHAUST MANIFOLD

    EXHAUST MANIFOLD
    REMOVAL AND INSTALLATION <4G1>
    M1151003300568

    29 3 Nm

    6
    29 3 Nm

    44 5 Nm

    17 2 Nm

    N9

    29 3 Nm

    29 3 Nm

    4
    24 4 Nm

    N5

    2N
    (Engine oil)
    35 6 Nm

    50 10 Nm

    1.
    2.
    <<A>> >>A<< 3.
    4.
    5.

    Removal steps
    Front exhaust pipe connection
    Exhaust pipe gasket
    Engine control oxygen sensor (front)
    Engine oil level gauge and guide
    assembly
    Engine oil filler O-ring

    AC303662 AB

    6.
    7.
    8.
    9.

    Removal steps (Continued)


    Exhaust manifold cover
    Exhaust manifold bracket
    Exhaust manifold
    Exhaust manifold gasket

    REMOVAL SERVICE POINT


    <<A>> ENGINE CONTROL OXYGEN SENSOR
    (FRONT) REMOVAL

    MD998770

    Engine control
    oxygen sensor
    (front)
    AC212566 AC

    Use special tool oxygen sensor wrench (MD998770)


    to remove the engine control oxygen sensor (front).

    INTAKE AND EXHAUST

    15-9

    EXHAUST MANIFOLD

    INSTALLATION SERVICE POINT


    >>A<< ENGINE CONTROL OXYGEN SENSOR
    (FRONT) INSTALLATION

    MD998770

    Engine control
    oxygen sensor
    (front)
    AC212566 AC

    Use special tool oxygen sensor wrench (MD998770)


    to install the engine control oxygen sensor (front).

    REMOVAL AND INSTALLATION <4G6>


    M1151003300579

    Pre-removal and Post-installation Operation


    Under cover Removal and Installation

    10 N

    49 5 Nm

    29 3 Nm
    14 1 Nm

    29 3 Nm
    49 9 Nm

    44 5 Nm

    7
    5
    6
    9.0 2.0 Nm

    49 5 Nm

    14 1 Nm

    35 6 Nm

    44 5 Nm

    2N
    1

    50 10 Nm

    1.
    2.
    <<A>> >>A<< 3.
    4.
    5.
    6.

    Removal steps
    Front exhaust pipe connection
    Exhaust pipe gasket
    Engine control oxygen sensor (front)
    Exhaust manifold cover
    Exhaust manifold bracket
    Starter cover

    AC303680 AB

    7.
    8.
    9.
    10.

    Removal steps (Continued)


    Starter cover bracket
    Engine hanger
    Exhaust manifold
    Exhaust manifold gasket

    INTAKE AND EXHAUST

    15-10

    EXHAUST MANIFOLD

    REMOVAL SERVICE POINT

    INSTALLATION SERVICE POINT

    <<A>> ENGINE CONTROL OXYGEN SENSOR


    (FRONT) REMOVAL

    >>A<< ENGINE CONTROL OXYGEN SENSOR


    (FRONT) INSTALLATION

    MD998770

    MD998770

    Engine control
    oxygen sensor
    (front)

    Engine control
    oxygen sensor
    (front)

    AC212566 AC

    Use special tool oxygen sensor wrench (MD998770)


    to remove the engine control oxygen sensor (front).

    AC212566 AC

    Use special tool oxygen sensor wrench (MD998770)


    to install the engine control oxygen sensor (front).

    INSPECTION
    M1151003400543

    Check the following points; replace the part if a


    problem is found.
    Exhaust Manifold Check
    1. Check for damage or cracking of any part.
    2. Using a straight edge and a feeler gauge, check
    for distortion of the cylinder head installation
    surface.
    Standard value: 0.15 mm or less
    Limit: 0.20 mm

    INTAKE AND EXHAUST

    15-11

    EXHAUST PIPE AND MAIN MUFFLER

    EXHAUST PIPE AND MAIN MUFFLER


    REMOVAL AND INSTALLATION
    M1151008700301

    <4G1>

    13 2 Nm

    13 2 Nm

    45 5 Nm

    N8

    6
    45 5 Nm
    59 10 Nm

    7N
    9

    50 10 Nm

    AC303694 AB

    <4G6>

    13 2 Nm

    45 5 Nm

    N8

    13 2 Nm

    6
    45 5 Nm
    59 10 Nm

    7N
    9

    50 10 Nm

    1.
    3.
    4.

    2.
    3.
    7.

    Exhaust main muffler removal


    steps
    Exhaust main muffler
    Exhaust pipe gasket
    Exhaust muffler hanger
    Centre exhaust pipe removal
    steps
    Centre exhaust pipe
    Exhaust pipe gasket
    Exhaust pipe gasket

    AC303695AB

    <<A>> >>A<< 5.
    6.
    7.
    8.
    9.

    Front exhaust pipe removal


    steps
    Engine control oxygen sensor
    (rear)
    Front exhaust pipe
    Exhaust pipe gasket
    Exhaust pipe gasket
    Exhaust muffler hanger

    INTAKE AND EXHAUST

    15-12

    EXHAUST PIPE AND MAIN MUFFLER

    REMOVAL SERVICE POINT

    INSTALLATION SERVICE POINT

    <<A>> ENGINE CONTROL OXYGEN SENSOR


    (REAR) REMOVAL

    >>A<< ENGINE CONTROL OXYGEN SENSOR


    (REAR) INSTALLATION

    MD998770

    Engine control
    oxygen sensor
    (rear)
    AC212566 AD

    Use special tool oxygen sensor wrench (MD998770)


    to remove the engine control oxygen sensor (rear).

    MD998770

    Engine control
    oxygen sensor
    (rear)
    AC212566 AD

    Use special tool oxygen sensor wrench (MD998770)


    to install the engine control oxygen sensor (rear).

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