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).