15-1

INTAKE AND
EXHAUST
CONTENTS

15109000250

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2

INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE SPECIFICATION . . . . . . . . . . . . . . . . . . 2

EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . . 6

SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

EXHAUST PIPE AND MAIN MUFFLER . . . . . . 8

15-2

INTAKE AND EXHAUST -

General Information/Service Specification/Special Tool

GENERAL INFORMATION

15100010061

The intake manifold is made of an aluminium alloy,

and the shape provides an increased intake inertia
effect and has a good volumetric efficiency.

The exhaust manifold is made of stainless steel.

The exhaust pipe is divided into three parts; the
front pipe, the centre pipe, and the main muffler.

SERVICE SPECIFICATION

15100030197

Items

Standard value

Limit

Manifold distortion of the installation surface mm

0.15 or less

0.20

SPECIAL TOOL
Tool

15100060066

Number

Name

Use

MD998770

Oxygen sensor
wrench

Removal/Installation of oxygen sensor

15-3

INTAKE AND EXHAUST - Intake Manifold

INTAKE MANIFOLD

15100300441

REMOVAL AND INSTALLATION

<4G6>
Pre-removal and Post - installation Operation
D Engine Coolant Draining and Supplying
(Refer to GROUP 14 - On-vehicle Service.)
D Engine Cover Removal and Installation
D Air Cleaner Assembly Removal and Installation

D
D

Ignition Coil Removal and Installation

(Refer to GROUP 16.)
Throttle Body Removal and Installation
(Refer to GROUP 13A.)

20 Nm

10 - 12 Nm

20 Nm

15

4
13

18

12

14
5
10

9 Nm

1
30 Nm

9
11
30 Nm

9 Nm

16
24 Nm

17

Removal steps
1. Engine harness connector and clamp
2. Earth cable connection
3. PCV hose
4. Brake booster vacuum hose
connection
5. Vacuum hose connection
6. Purge solenoid valve
7. Vacuum pipe and hose assembly
8. Intake manifold and air intake plenum
resonator assembly connecting bolt
9. Intake manifold stay and air intake
plenum resonator assembly
connecting bolt

10. Intake manifold and stay connecting

bolt
11. Intake manifold and EGR valve
support connecting bolt
12. Intake manifold
13. Intake manifold gasket
14. Gasket
15. Air intake plenum resonator assembly
16. Power steering hose clamp
17. Alternator harness clamp
18. Intake manifold stay

15-4

INTAKE AND EXHAUST - Intake Manifold

<4G9>
Pre-removal and Post - installation Operation
D Engine Coolant Draining and Supplying
(Refer to GROUP 14 - On-vehicle Service.)
D Engine Cover Removal and Installation
D Ignition Coil Removal and Installation
(Refer to GROUP 16.)

D
D

Air Cleaner Assembly Removal and Installation

Throttle Body Removal and Installation
(Refer to GROUP 13B.)

10 - 12 Nm

7
9 Nm

20 Nm

9 Nm

10

26
9
2
25
24

16

14

9 Nm

19 Nm
9 Nm

22
5

23

11

13

15

24 Nm

25 - 32 Nm

18

21

17
19 Nm

12
10 - 12 Nm
25 - 32 Nm

19

19 20
19 Nm

INTAKE AND EXHAUST - Intake Manifold

Intake manifold removal steps
1. Brake booster vacuum pipe
2. Brake booster vacuum hose
3. Harness connector
4. Vacuum hose
5. Vacuum pipe and pipe
6. Purge control solenoid valve
7. Harness clamp
8. PCV hose connection
9. Water hose connection
D Front exhaust pipe assembly
(Refer to P.15-8.)
10. Intake manifold and air intake plenum
resonator assembly connecting bolt
11. Intake manifold and stay connecting
bolt
12. Intake manifold and EGR valve
support connecting bolt
13. EGR pipe gasket
14. Intake manifold assembly
15. Intake manifold gasket

15-5

16. Air intake plenum resonator assembly

17. Harness connector clamp
18. Intake manifold stay
EGR valve removal steps
3. Harness connector
12. Intake manifold and EGR valve
support connecting bolt
13. EGR valve gasket
19. Water hose connection
20. EGR valve
21. EGR valve gasket
22. EGR valve support
23. EGR valve gasket
Air bypass valve removal steps
14. Intake manifold assembly
24. Water hose connection
25. Air bypass valve
26. Air bypass valve gasket

INSPECTION

15100310161

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

15-6

INTAKE AND EXHAUST - Exhaust Manifold

EXHAUST MANIFOLD

15100330440

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation
Under Cover Removal and Installation

<4G6>
49 Nm

12 - 15 Nm

6
29 Nm
49 Nm
34 Nm

44 Nm

<4G9>

18 Nm

29 Nm

13 Nm

29 Nm

12 - 15 Nm

4
35 Nm

5
3
34 Nm

19 Nm

2
1

44 Nm

Removal steps
1. Front exhaust pipe connection
2. Gasket
3. Oil level gauge assembly <4G9>
4. Heat protector

5. Exhaust manifold bracket <4G9>

6. Exhaust manifold
7. Exhaust manifold gasket

INTAKE AND EXHAUST - Exhaust Manifold

INSPECTION

15-7
15100340061

EXHAUST 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

15-8

INTAKE AND EXHAUST - Exhaust Pipe and Main Muffler

EXHAUST PIPE AND MAIN MUFFLER

15100540355

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation
Under Cover Removal and Installation

Hanger installation
bolt tightening torque

5, 8, 13
13 Nm

1
5

13 Nm

14
34 Nm

12

13
15

54 Nm

54 Nm

44 Nm

49 Nm

8
10

49 Nm

11

49 Nm

Main muffler removal steps

1. Main muffler assembly
2. Gasket
3. Hanger
Center exhaust pipe removal steps
AA" "AA 2. Oxygen sensor <4G6>
3. Center exhaust pipe
4. Gasket
7. Gasket
8. Hanger

Catalytic converter removal steps

6. Catalytic converter
7. Gasket
11. Gasket
Front exhaust pipe removal steps
AA" "AA 9. Oxygen sensor
10. Front exhaust pipe
11. Gasket
12. Gasket
13. Hanger
14. Front hanger bracket
15. Front exhaust pipe bracket

REMOVAL SERVICE POINT

AA" OXYGEN SENSOR REMOVAL

INSTALLATION SERVICE POINT

"AA OXYGEN SENSOR INSTALLATION

MD998770