08 Intake Exhaust

Engine/hybrid system
Intake / exhaust
Intake system (FA20)

Parts location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IE-2
On-vehicle inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IE-4
Circuit figure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IE-8
Intake manifold ASSY (FA20)
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IE-10
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IE-15
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IE-21
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IE-25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IE-28
Chamber (FA20) IE
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IE-30
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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IE-31
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IE-32
Unit inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IE-33
Exhaust manifold (FA20)
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IE-34
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IE-35
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IE-36
Exhaust pipe ASSY (FA20)
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IE-37
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IE-39
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IE-44
IE–2 Intake / exhaust － Intake system (FA20)
Intake system (FA20)

Engine/hybrid
Intake / exhaust
system
Parts location
IE
ECM
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Intake air flow meter S/A
IN-03202
Intake / exhaust － Intake system (FA20)
IE–3
Throttle body ASSY
IE
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Crankshaft position sensor
IN-10079
On-vehicle inspection
1. Visual inspection
(1) Make sure that there is no air suction at the locations shown in the figure.
*A:
IE
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IN-10052
IE–5
*B:
IE
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IN-10053
Captions in illustration
*A Transmission M/T *B Transmission A/T
NOTE:
If the any of the parts on the intake side is disconnected, cracked or damaged, improper idling will be caused.
2. Check of air cleaner filter element SUB-ASSY

(1) Remove the two clips from the air cleaner case (rear).
(2) Lift the air cleaner case (rear) and release the two claws which
engage in the air cleaner case (front).
IE
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(3) Lift the air cleaner case (rear) at an angle as shown in the figure
and remove the air cleaner filter element.
(4) Check the air cleaner filter element for excessive dirt.
Criteria: Not excessively dirty
CAUTION:
If it is excessively dirty, replace the air cleaner filter element.
(5) When cleaning the air cleaner filter element, clean it by blowing air.
(6) Lift the air cleaner case (rear) at an angle and install the air cleaner
filter element.
(7) Engage the two claws of air cleaner case (rear) to the air cleaner
case (front).
IE–7
(8) Install the two clips.

CAUTION:
• Make sure that the positioning protrusions at the right and left
sides of the air cleaner case do not ride over.
• Be sure to engage the two claws at the lower side of air cleaner
case.
*1 Positioning protrusion
IE
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Circuit figure
IE

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*1 Engine control computer *2 Intake air flow meter ASSY
*3 Throttle body ASSY *4 Air cleaner
*5 Crankshaft position sensor - -
IE–9
28
A33 SLE2
22
5
VG A33 VG
* *
29
4
3 E2G A33 E2G
EFI MAIN 1 RALAY +B
12
1
THA A33 THA
2
E2
C16
MASS AIR FLOW METER IE
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16
NE+ 1
A34 NE+
27
NE- 2
A34 NE-
3
C33
CRANKSHAFT POISITION
SENSOR
28
4
VTA2 A36 VTA2
18
6
VTA1 A36 VTA1
* 2
M+ 2 A36 M+
1
1
M- A36 M-
19
VC 5 A36 VC
29
3
E2 A36 E1
C15 ECM
THROTTLE WITH MOTOR BODY ASSEMBLY
*:Shielded
IN-10113
IE–10 Intake / exhaust － Intake manifold ASSY (FA20)
Intake manifold ASSY (FA20)

Engine/hybrid
Intake / exhaust
system
Exploded view
2.0 (20,1.5)
6.0 (61,4.4) 2.0 (20,1.5)

x3
IE
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Ventilation hose No.2
Air cleaner case SUB-ASSY
N•m {kgf•cm, ft•lbf} : Specified torque

IN-03280
Intake / exhaust － Intake manifold ASSY (FA20)
IE–11
Transmission A/T:
Injector driver
Intake manifold protector
(bank 1 side) Fuel delivery pipe (bank 2 side)
19 {194, 14.0}
19 {194, 14.0} 11 {112, 8.1} x2

x2
x3 Wiring harness clamp bracket

(bank 2 side)
IE
6.4 {65, 4.7} Fuel delivery pipe No.3
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19 {194, 14.0} x2
x2
Seal ring
Seal ring
x2
Fuel delivery pipe
(bank 1 side)
x2 19 {194, 14.0}
Fuel hose
Non-reusable part
N*m {kgf*cm, ft*lbf} : Specified torque

IN-10054
Transmission M/T:
Injector driver

(bank 1 side)
Fuel delivery pipe (bank 2 side)
19 {194, 14.0}
x2 19 {194, 14.0}
x3 x2

(bank 2 side)
IE 6.4 {65, 4.7}

Fuel delivery pipe No.3
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19 {194, 14.0} x2
x2
Seal ring
Seal ring
Fuel delivery pipe x2
(bank 1 side)
x2 19 {194, 14.0}
Fuel hose
Non-reusable part

IN-10055
IE–13
Transmission A/T:
Engine cover
Ventilation hose SUB-ASSY No. 1
Cap
4.0 {41, 3.0}
Air pressure sensor ASSY

6.4 {65, 4.7}
O-ring
Fuel delivery
25 {255, 18.4} x6
pipe SUB-ASSY
IE
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6.4 {65, 4.7}
Gasket
Intake manifold
x2
x4 Gasket
8.0 {82, 5.9}
Purge control solenoid valve
Throttle body Fuel vapor feed hose No. 2

ASSY (with motor)
Fuel vapor feed hose No. 1
Non-reusable part
IN-10056
Transmission M/T:
Ventilation hose Union to
check valve hose
3.4 {35, 2.5}
Air pressure sensor ASSY

6.4 {65, 4.7}
O-ring
Fuel delivery
pipe SUB-ASSY
IE 25 {255, 18.4} x6
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6.4 {65, 4.7}
Gasket
Intake manifold
x2
x4
Gasket
8.0 {82, 5.9}
Purge control solenoid valve
Throttle body Fuel vapor feed hose No. 2

ASSY (with motor)
Compressor ASSY Fuel vapor feed hose No. 1

(with magnet clutch)
36 {367, 26.6}
x2
36 {367, 26.6}
Non-reusable part
IN-10057
IE–15
REMOVAL
1. CHECK FUEL PUMP OPERATION AND INSPECT FOR FUEL LEAK (See page FU - 3)
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (See page IN - 6)
3. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE (See page EM - 75)
4. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY
(1) Remove the 4 bolts and the throttle with motor body assembly.
5. DISCONNECT FUEL HOSE No. 1 (See page FU - 23)

6. DISCONNECT FUEL HOSE No. 2 (See page FU - 23) IE
7. DISCONNECT PURGE HOSE (See page FU - 23)
8. REMOVE INJECTOR DRIVER (See page FU - 43)
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9. REMOVE INTAKE MANIFOLD PROTECTOR (for Bank 2) (See page FU - 23)
10. REMOVE INTAKE MANIFOLD PROTECTOR (for Bank 1) (See page FU - 22)
11. DISCONNECT FUEL DELIVERY PIPE SUB-ASSEMBLY
D
(1) Remove the bolt and disconnect the fuel delivery pipe sub-assem-
bly.
(2) Disconnect the No. 2 fuel vapor feed hose and move the fuel deliv-
ery pipe toward the front of the vehicle.
Text in Illustration
*a Transmission A/T
*b Transmission M/T
IN-10063
12. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (TRANSMISSION

A/T)
(1) Disengage the 3 craws and remove the No. 1 engine cover sub-
assembly.
NOTE:
Release the tabs from the front side of the vehicle.
IE
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13. V-BELT REMOVAL (TRANSMISSION M/T) (See page EM - 5)
14. COMPRESSOR ASSY (WITH MAGNET CLUTCH) MOVING (TRANS-
MISSION M/T)
(1) Remove the 3 bolts and hold the compressor ASSY (with magnet
clutch) by hand.
(2) Replace bolt A in the figure to a bolt of approximately 100 mm
{3.937 in} in length, and move the compressor ASSY (with magnet
clutch) towards the front of the vehicle.
IN-10064
15. DISCONNECT NO. 2 VACUUM HOSE (for Manual Transmission) (See page BR - 28)
IE–17
16. DISCONNECT VENTILATION HOSE

D
(1) Disconnect the ventilation hose.
*a Transmission A/T
*b Transmission M/T
IE
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IN-10058
17. REMOVE INTAKE MANIFOLD

D
(1) Disconnect the manifold absolute pressure sensor connector.
*a Transmission A/T
*b Transmission M/T
IN-10059
(2) Disconnect the purge control solenoid valve connector.

D
*a Transmission A/T
*b Transmission M/T
IE
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IN-10060
(3) Release the three clips and disconnect the wiring harness. (Trans-
mission A/T)
IN-10061
(4) Disengage the clamp and disconnect the engine wire harness.
D
*a Transmission A/T
*b Transmission M/T
IN-10062
IE–19
(5) Disengage the 2 clamps and disconnect the 4 connectors.

*a Text in Illustration
*a Bank 2 Side
*b Bank 1 Side
*b
IE
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(6) Disconnect the fuel pump connector.
(7) Remove the 6 bolts, intake manifold and 2 gaskets.

*a Text in Illustration
*a Bank 2 side (transmission A/T)
*b Bank 1 side (transmission A/T)
*c Bank 2 side (transmission M/T)
*d Bank 1 side (transmission M/T)
*b
IE
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F
IN-10065
IE–21
DISASSEMBLY
1. REMOVE MANIFOLD ABSOLUTE PRESSURE SENSOR
D
(1) Remove the bolt and manifold absolute pressure sensor from the
intake manifold.
*a Transmission A/T
*b Transmission M/T
IE
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IN-10066
(2) Remove the O-ring from the manifold absolute pressure sensor.
2. REMOVE PURGE CONTROL SOLENOID VALVE

D
(1) Disconnect the No. 1 fuel vapor feed hose from the intake mani-
fold.
*a Transmission A/T
*b Transmission M/T
IE
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IN-10067
(2) Remove the nut and purge control solenoid valve.

D
*a Transmission A/T
*b Transmission M/T
IN-10068
3. REMOVE CAP (for Automatic Transmission)

(1) Remove the cap from the intake manifold.
IN-03281
IE–23
4. REMOVE FUEL DELIVERY PIPE (for Bank 2)

(1) Disconnect the No. 3 fuel delivery pipe sub-assembly from the fuel delivery pipe (for bank 2).
CAUTION:
• If the connector and pipe are stuck, pinch the fuel delivery pipe No. 3 by hand and push and pull the connector to disconnect
it.
• Do not allow any scratches or foreign matter on the parts when disconnecting them, as the No. 3 fuel delivery pipe joint con-
tains the O-rings that seal the plug.
• Do not use any tools to separate the pipe and connector.
• Do not forcibly bend, twist or turn the nylon tube.
• If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then, discon-
nect the main tube.
• Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the main tube.
• Check that the top hat cannot be pulled out.
D

IE
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E
IN-10069
*a Transmission A/T *b Transmission M/T
*1 Retainer *2 No. 3 Fuel Delivery Pipe Connector
*3 Nylon Tube *4 O-ring
*5 fuel delivery pipe *6 Top Hat
(2) Remove the 2 bolts and the fuel delivery pipe (for bank 2) from the
D
intake manifold.
*a Transmission A/T
*b Transmission M/T
IE
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IN-10070
5. REMOVE FUEL DELIVERY PIPE (for Bank 1)

NOTE:
Use the same procedure described for the fuel delivery pipe (for bank 2).
6. REMOVE NO. 3 FUEL DELIVERY PIPE
D
(1) Disengage the 3 clamps and remove the No. 3 fuel delivery pipe
from the intake manifold. (Transmission A/T)
(2) Disengage the 2 clamps and remove the No. 3 fuel delivery pipe
from the intake manifold. (Transmission M/T)
*a Transmission A/T
*b Transmission M/T
IN-10071
IE–25
REASSEMBLY
1. INSTALL NO. 3 FUEL DELIVERY PIPE
D
(1) Install the No. 3 fuel delivery pipe to the intake manifold with the 3
clamps. (Transmission A/T)
(2) Install the No. 3 fuel delivery pipe to the intake manifold with the 2
clamps. (Transmission M/T)
*a Transmission A/T
*b Transmission M/T
IE
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IN-10071
2. Fuel delivery pipe installation (bank 2 side)

(1) Apply gasoline to two new seal rings and install them to the fuel injector ASSY.
CAUTION:
Make sure there is no damage to or foreign matter in seal ring grooves of the injector.
(2) With the fuel injector ASSY installed on the fuel delivery pipe (bank 2 side), install it to the intake manifold.
CAUTION:
• Be careful not to twist the seal ring.
• After it is attached to the fuel delivery pipe (bank 2 side), confirm that it can be rotated relatively lightly. If it cannot be rotated,
remove the injector and repeat the work after replacing the seal rings with new ones.
(3) With 2 bolts, install the fuel delivery pipe (bank 2 side) to the intake
D
manifold.
Standard value:T=19N·m {194kgf·cm} {14ft·lbf}
*a Transmission A/T
*b Transmission M/T
IN-10070
(4) Align the axis of the fuel delivery pipe NO.3 connector and the axis of the pipe, connect them, and push the retainer until
you hear the click.
CAUTION:
• Before starting the work, check that there is no damage to or foreign material on the fuel delivery pipe NO.3 connector and
the pipe connection.
• After connecting fuel delivery pipe NO.3, check that the fuel delivery pipe NO.3 connector and the pipe are securely
attached.
3. INSTALL FUEL DELIVERY PIPE (for Bank 1)
NOTE:
Use the same procedure described for the fuel delivery pipe (for bank 2).
4. INSTALL CAP (for Automatic Transmission)
(1) Install the cap to the intake manifold.
IE
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IN-03281
5. INSTALL PURGE CONTROL SOLENOID VALVE
D
(1) Connect the No.1 fuel vapor feed hose to the intake manifold.
*a Transmission A/T
*b Transmission M/T
IN-10067
IE–27
(2) Install the nut and purge control solenoid valve to the intake mani-
D
fold.
Standard value:T=6.4N·m {65kgf·cm} {4.7ft·lbf}
*a Transmission A/T
*b Transmission M/T
IE
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IN-10068
6. INSTALL MANIFOLD ABSOLUTE PRESSURE SENSOR

(1) Apply engine oil to the contact surfaces of the new O-ring on manifold absolute pressure sensor.
(2) Install a new O-ring to the manifold absolute pressure sensor.

(3) Install the manifold absolute pressure sensor to the intake mani-
D
fold with the bolt.
Standard value:T=4.0N·m {41kgf·cm} {3.0 ft·lbf} (Transmis-
sion A/T)
Standard value:T=3.4N·m {35kgf·cm} {2.5 ft·lbf} (Transmis-
sion M/T)
*a Transmission A/T
*b Transmission M/T
IE
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IN-10066
INSTALLATION
1. INSTALL INTAKE MANIFOLD
(1) Install the 2 new gaskets to the intake manifold.
(2) Install the intake manifold with the 6 bolts.
Standard value:T=25N·m {255kgf·cm} {18.4ft·lbf}
(3) Engage the 4 connectors and connect the wire harness.
(4) Connect the fuel pump connector.
(5) Engage the clamp and connect the engine wire harness.
(6) Engage the three clips and connect the wiring harness. (Transmission A/T)
(7) Connect the purge control solenoid valve connector.
(8) Connect the manifold absolute pressure sensor connector.
2. CONNECT VENTILATION HOSE
(1) Connect the ventilation hose.
3. CONNECT NO. 2 VACUUM HOSE (for Manual Transmission) (See page BR - 30)
4. Installation of compressor ASSY (with magnet clutch) (transmission M/T) (See page AC - 148)
5. Installation of V-belt (transmission M/T) (See page EM - 7)
6. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (TRANSMISSION A/T)
(1) Engage the 3 claws and install the No. 1 engine cover sub-assembly.
7. CONNECT FUEL DELIVERY PIPE SUB-ASSEMBLY
(1) Connect the No. 2 fuel vapor feed hose.
(2) Install the bolt and connect the fuel delivery pipe sub-assembly.
8. INSTALL INTAKE MANIFOLD PROTECTOR (for Bank 2) (See page FU - 28)
9. INSTALL INTAKE MANIFOLD PROTECTOR (for Bank 1) (See page FU - 28)
10. INSTALL INJECTOR DRIVER (See page FU - 44)
11. CONNECT PURGE HOSE (See page FU - 28)
12. CONNECT FUEL HOSE NO. 2 (See page FU - 28)
13. CONNECT FUEL HOSE NO. 1 (See page FU - 28)
14. CONNECT THROTTLE WITH MOTOR BODY ASSEMBLY
(1) Install a new gasket to the intake manifold.
IE–29
(2) Install the 4 bolts and throttle with motor body assembly to intake manifold.
15. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE (See page EM - 114)
16. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
17. INSPECT FUEL PUMP OPERATION AND INSPECT FOR FUEL LEAK (See page FU - 10)
18. INSPECT THROTTLE WITH MOTOR BODY ASSEMBLY (See page ES - 673)
IE
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IE–30 Intake / exhaust － Chamber (FA20)
Chamber (FA20)
Engine/hybrid
Intake / exhaust
system
Exploded view
Grommet
6.0 (61,4.4) x2
2.0 (20,1.5)
2.0 (20,1.5)
Hose
IE Chamber ASSY
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Air cleaner duct
N•m {kgf•cm, ft•lbf} : Specified torque

IN-03279
Intake / exhaust － Chamber (FA20)
IE–31
Removal
1. Hose removal
(1) Disconnect the hose.
(2) Release the two clamps and remove the hose from the grommet.
IE
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2. Duct removal
(1) Loosen the hose clamp.
IN-03323
(2) Remove the two bolts and remove the duct and chamber ASSY as
a unit.
IE–32 Intake / exhaust － Chamber (FA20)
3. Chamber ASSY removal

(1) Loosen the hose clamp and remove the chamber ASSY.
Installation
1. Chamber ASSY installation
(1) Install the chamber ASSY with the hose clamp.
2. Duct installation
IE (1) Install the duct and chamber ASSY as a unit with the two bolts.
(2) Install the duct with the hose clamp.
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3. Hose installation
(1) Engage the two clamps and install the hose.
(2) Insert the hose until the flange at the hose end contacts the grom-
C
met.
*1 Grommet
*a Flange
C
CAUTION:
When inserting the hose end, insert the hose so that the grommet rub-
ber is not engulfed to avoid water leakage.
(3) Make sure from the passenger room side that the hose end is inserted properly.
(4) Connect the hose and install the hose.
Intake / exhaust － Chamber (FA20)
IE–33
Unit inspection
1. Chamber ASSY check
(1) Check that air does not comes out easily from the IN side when air
is blown into the chamber from the EX side.
*a EX side
C D *b IN side
IE
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IE–34 Intake / exhaust － Exhaust manifold (FA20)
Exhaust manifold (FA20)

Engine/hybrid
Intake / exhaust
system
Exploded view
Exhaust pipe ASSY FR
13 (133, 9.6) x2
x2
Gasket x2
Gasket
x2
18 (184, 13.3)
IE x2
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x2
x2
42.5 (433, 31.3)
13 (133, 9.6)
50 (510, 36.9)
13 (133, 9.6)
Under cover COMPL T/M
Under cover front AL

x7
7.5 (77, 5.5)
x4
30 (306, 22.1) x8
x7 7.5 (77, 5.5)
Non-reusable part
N*m {kgf*cm, ft*lbf} : Tightening torque
EX-10038
Intake / exhaust － Exhaust manifold (FA20)
IE–35
13 (133, 9.6)
Exhaust pipe SUB-ASSY FR
42.5 (433, 31.3)

x2
Gasket
Exhaust manifold
Gasket
IE
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x2
*1
13 (133, 9.6)
30 (306, 22.1)
x6
Non-reusable part
*1: x15 (Transmission A/T)
N*m {kgf*cm, ft*lbf} : Tightening torque x20 (Transmission M/T)
EX-10039
Removal
1. Disconnection of the battery ground terminal (Refer to IN - 6)
2. Disconnect the connector for air / fuel ratio sensor and the 2 clamps. (Refer to ES - 713)
3. Disconnect the connector for oxygen sensor and the 2 clamps. (Refer to ES - 716)
4. Removal of exhaust pipe ASSY FR (Refer to IE - 40)
IE–36 Intake / exhaust － Exhaust manifold (FA20)
5. Exhaust manifold removal

(1) Remove the two nuts and remove the exhaust pipe SUB-ASSY
FR.
(2) Remove the gasket.
(3) Remove the six nuts and remove the exhaust manifold.
(4) Remove the two gaskets.
IE
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Installation
1. Exhaust manifold installation
(1) Install two new gaskets.
(2) Install the exhaust manifold with the six nuts.
(3) Install a new gasket to the exhaust pipe SUB-ASSY FR installation portion of exhaust manifold.
(4) Install the exhaust pipe SUB-ASSY FR with the two nuts.
2. Installation of exhaust pipe ASSY FR (Refer to IE - 46)
3. Install the connector for oxygen sensor connector and the two clamps. (Refer to ES - 718)
4. Install the connector for air/fuel ratio sensor and the 2 clamps. (Refer to ES - 714)
5. Connection of the battery ground terminal
6. Exhaust gas leakage check
(1) Make sure that there is no exhaust gas leakage from the connections of exhaust pipes and the mounting portion of each
sensor.
Intake / exhaust － Exhaust pipe ASSY (FA20)
IE–37
Exhaust pipe ASSY (FA20)

Engine/hybrid
Intake / exhaust
system
Exploded view
Exhaust pipe ASSY FR
13 (133, 9.6) x2
x2
Gasket x2
Gasket
x2
18 (184, 13.3)
x2
IE
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x2
x2
42.5 (433, 31.3)
13 (133, 9.6)
50 (510, 36.9)
13 (133, 9.6)
Under cover COMPL T/M
Under cover front AL

x7
7.5 (77, 5.5)
x4
30 (306, 22.1) x8
x7 7.5 (77, 5.5)
Non-reusable part
N*m {kgf*cm, ft*lbf} : Tightening torque
EX-10038
IE–38 Intake / exhaust － Exhaust pipe ASSY (FA20)
With tail pipe baffle:
Tail pipe baffle

x2
7.5 (77, 5.5) x2
IE Cushion rubber x4
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x2
Exhaust tail pipe ASSY
Gasket
Cushion rubber 48 (490, 35.4)

x2
Exhaust pipe ASSY CTR
x2
x2
Gasket
x2
18 (184,13.3)
Non-reusable part

EX-10047
IE–39
13 (133, 9.6)
Exhaust pipe SUB-ASSY FR
42.5 (433, 31.3)

x2
Gasket
Exhaust manifold
Gasket IE
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x2
*1
13 (133, 9.6)
30 (306, 22.1)
x6
Non-reusable part
*1: x15 (Transmission A/T)
N*m {kgf*cm, ft*lbf} : Tightening torque x20 (Transmission M/T)
EX-10039
Removal
1. Under cover front AL removal
(1) Remove the 12 bolts, release the seven clips, and then remove the
under cover front AL.
2. Under cover COMPL T/M removal

(1) Remove the seven bolts to remove the under cover COMPL T/M.
3. Removal of exhaust pipe ASSY FR

(1) Remove the two nuts and remove the exhaust pipe ASSY FR.
IE
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(2) Remove the two nuts, two bolts and two compression springs to
remove the exhaust pipe ASSY CTR.
(3) Remove the bolt and remove the exhaust pipe ASSY FR.
(4) Remove the two gaskets.
IE–41
4. Removal of exhaust pipe ASSY CTR

(1) Remove the two nuts and two bolts to remove the exhaust tail pipe
ASSY.
(2) Remove the cushion rubber, and remove the exhaust pipe ASSY
CTR.
(3) Remove the gasket.
IE
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5. Exhaust tail pipe ASSY removal
(1) Remove the four cushion rubbers and remove the exhaust tail pipe
ASSY.
6. Tail pipe baffle removal (with tail pipe baffle)

(1) Remove the two bolts and remove the two tail pipe baffles.
7. Exhaust manifold removal (Refer to IE - 36)
8. Removal of exhaust pipe SUB-ASSY FR
(1) Front strut tower bar LH removal (Refer to FP - 5)
(2) Removal of flexible V-shaped bar LH (tS model) (Refer to FP - 5)
(3) Front strut tower bar RH removal (Refer to FP - 4)
(4) Removal of flexible V-shaped bar RH (tS model) (Refer to FP - 5)
(5) Removal of air cleaner case SUB-ASSY (Refer to EM - 75)
(6) Engine wiring disconnection

(a)Release the four clamps and disconnect the engine wiring.
FU-07426
(b)Release the clamp and disconnect the bulkhead harness.
IG-10005
(c)Remove the bolt and three clamps, and then disconnect the
engine wiring. (Transmission A/T)
IE
cardiagn.com
FU-07427
(7) Remove the 2 nuts on the engine mount.
(8) Tie the joint pipe to the front suspension crossmember SUB-ASSY
with rope.
NOTE:
This procedure is necessary to prevent the joint pipe from falling
off.
IE–43
(9) Install the SST to the cylinder block.

*1 12281-38150

*2 90119-14120
SST 12281-38150, 90119-14120

IG-02168
(10) Release the clamp and disconnect the engine wiring.

*1 LH
*2 RH
NOTE:
This procedure is required to prevent the engine wiring from dam-
aging.
IE
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IG-02169
(11) Install the SST to the vehicle.
556
556 556
IG-02180
SST 99099AJ000, 18679AA020

CAUTION:
• When installing the SST to the vehicle, do not damage the engine wiring.
• Use a shackle with a load capacity of 250 kg (551 lb) or more.
(12) Lift the engine ASSY a little bit at a time until the stud bolt of the engine mount is removed from the front crossmember.
CAUTION:
• To avoid the damage to the SST, apply grease or lubricant to the threaded portion.
• To avoid the damage to the vehicle and parts, perform lifting operation a little bit at a time while checking the clearance in
each part.
• Lift up the engine ASSY until the position where the intake manifold (#4) and A/C suction hose contact lightly.
• Insert a cloth etc. between the intake manifold (#4) and A/C suction hose to protect the parts of them.
(13) Install the SST between engine mount and front crossmember.
SST 18632AA020
IE
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556
(14) Remove the rope which secures the exhaust pipe SUB-ASSY FR
to the front suspension crossmember SUB-ASSY.
(15) Remove the exhaust pipe SUB-ASSY FR.
Installation
1. Exhaust pipe SUB-ASSY FR installation
(1) Tie the exhaust pipe SUB-ASSY FR to the front suspension crossmember SUB-ASSY with the rope.
NOTE:
This operation is required to avoid dropping the exhaust pipe SUB-ASSY FR.
2. Removal of SST
(1) Using the SST, lift the engine ASSY.
SST 99099AJ000, 18679AA020
(2) Remove the SST.

SST 18632AA020
556
IE–45
(3) Install the two nuts of the new engine mounting.

(4) Remove the rope which secures the joint pipe to the front suspension crossmember SUB-ASSY.
(5) Remove the SST from the vehicle.
(6) Remove the SST from the cylinder block.
(7) Connect the engine wiring with the clamp.

*1
*2
LH
RH
IE
cardiagn.com

IG-02169
(8) Engine wiring connection

(a)Connect the engine wiring with the bolt and three clamps. (Transmission A/T)
(b)Using the clamp, connect the bulkhead harness.
(c)Using 4 clamps, connect the engine wire.
(9) Installation of air cleaner case SUB-ASSY (Refer to EM - 114)
(10) Front strut tower bar LH installation (Refer to FP - 5)
(11) Installation of flexible V-shaped bar LH (tS model) (Refer to FP - 5)
(12) Front strut tower bar RH installation (Refer to FP - 5)
(13) Installation of flexible V-shaped bar RH (tS model) (Refer to FP - 5)
3. Exhaust manifold installation (Refer to IE - 36)
4. Tail pipe baffle installation (with tail pipe baffle)

(1) As shown in the figure, align the notch of the tail pipe baffle and the
C
protrusion of the exhaust tailpipe ASSY, and push in until it hits the
tailpipe baffle stopper.
*a Cutout
*b Protrusion portion
*c Stopper
D
(2) Install the two tail pipe baffles with the two bolts.
E
EX-03210
5. Exhaust tail pipe ASSY installation

IE (1) Install the exhaust tail pipe ASSY with the four cushion rubbers.
6. Installation of exhaust pipe ASSY CTR
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(1) Install the exhaust pipe ASSY CTR with the cushion rubber.
(2) Install the exhaust pipe ASSY CTR to the exhaust tail pipe ASSY via a new gasket with the two bolts and two new nuts.
7. Installation of exhaust pipe ASSY FR
(1) Temporarily tighten the exhaust pipe ASSY FR to the bracket with the bolt.
(2) Install the exhaust pipe ASSY FR to the exhaust pipe ASSY CTR via a new gasket with the two nuts, two bolts and two
compression rings.
(3) Install the exhaust pipe ASSY FR to the exhaust pipe SUB-ASSY FR via a new gasket with the two nuts.
(4) Finally tighten the bolt for securing the bracket of exhaust pipe ASSY FR.
8. Exhaust gas leakage check
(1) Make sure that there is no exhaust gas leakage from the connections of exhaust pipes and the mounting portion of each
sensor.
9. Shift lever position check (transmission A/T) (Refer to AT - 210)
10. Under cover COMPL T/M installation
(1) Install the under cover COMPL T/M with the seven bolts.
11. Under cover front AL installation
(1) Install the under cover front AL with the 12 bolts and seven clips.
Bolt A
Bolt B
Standard value:Bolt A
T=30N·m {306kgf·cm} {22.1ft·lbf}
Standard value:Bolt B
T=7.5N·m {77kgf·cm} {5.5ft·lbf}

08 Intake Exhaust

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08 Intake Exhaust

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Engine/hybrid system

Intake system (FA20)

Intake system (FA20)

Throttle body ASSY

2. Check of air cleaner filter element SUB-ASSY

(8) Install the two clips.

Intake manifold ASSY (FA20)

6.0 (61,4.4) 2.0 (20,1.5)

Air cleaner case SUB-ASSY

N•m {kgf•cm, ft•lbf} : Specified torque

19 {194, 14.0} 11 {112, 8.1} x2

x3 Wiring harness clamp bracket

Intake manifold protector

N*m {kgf*cm, ft*lbf} : Specified torque

Intake manifold protector

Fuel delivery pipe (bank 2 side)

Intake manifold protector

IE 6.4 {65, 4.7}

N*m {kgf*cm, ft*lbf} : Specified torque

Air pressure sensor ASSY

Throttle body Fuel vapor feed hose No. 2

N*m {kgf*cm, ft*lbf} : Specified torque

3.4 {35, 2.5}

Air pressure sensor ASSY

Throttle body Fuel vapor feed hose No. 2

Compressor ASSY Fuel vapor feed hose No. 1

N*m {kgf*cm, ft*lbf} : Specified torque

5. DISCONNECT FUEL HOSE No. 1 (See page FU - 23)

12. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (TRANSMISSION

16. DISCONNECT VENTILATION HOSE

17. REMOVE INTAKE MANIFOLD

(2) Disconnect the purge control solenoid valve connector.

(5) Disengage the 2 clamps and disconnect the 4 connectors.

(7) Remove the 6 bolts, intake manifold and 2 gaskets.

2. REMOVE PURGE CONTROL SOLENOID VALVE

(2) Remove the nut and purge control solenoid valve.

3. REMOVE CAP (for Automatic Transmission)

4. REMOVE FUEL DELIVERY PIPE (for Bank 2)

5. REMOVE FUEL DELIVERY PIPE (for Bank 1)

2. Fuel delivery pipe installation (bank 2 side)

6. INSTALL MANIFOLD ABSOLUTE PRESSURE SENSOR

(2) Install a new O-ring to the manifold absolute pressure sensor.

N•m {kgf•cm, ft•lbf} : Specified torque

3. Chamber ASSY removal

Exhaust manifold (FA20)

Exhaust pipe ASSY FR

Under cover COMPL T/M

Under cover front AL

7.5 (77, 5.5)

N*m {kgf*cm, ft*lbf} : Tightening torque

Exhaust pipe SUB-ASSY FR

42.5 (433, 31.3)

5. Exhaust manifold removal

Exhaust pipe ASSY (FA20)

Exhaust pipe ASSY FR

Under cover COMPL T/M

Under cover front AL

7.5 (77, 5.5)

N*m {kgf*cm, ft*lbf} : Tightening torque

With tail pipe baffle:

Tail pipe baffle

7.5 (77, 5.5) x2

Cushion rubber 48 (490, 35.4)

Nm {kgfcm, ft*lbf} : Specified torque

Nm {kgfcm, ft*lbf} : Specified torque

Nm {kgfcm, ft*lbf} : Specified torque

Nm {kgfcm, ft*lbf} : Specified torque

Nm {kgfcm, ft*lbf} : Tightening torque

Nm {kgfcm, ft*lbf} : Tightening torque

Nm {kgfcm, ft*lbf} : Specified torque