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Pajero Workshop Manual
Pajero Workshop Manual
Pajero Workshop Manual
INTAKE AND
EXHAUST
CONTENTS
SERVICE SPECIFICATIONS
Items Standard value Limit
SEALANT
Item Specified sealant Remarks
Thread of the intake manifold mounting 3M Stud Locking No.4170 or equivalent Anaerobic sealant
bolts
SPECIAL TOOL
Tool Number Name Use
MD998770 Oxygen sensor Removal/Installation of oxygen sensor <6G7>
wrench
ON-VEHICLE SERVICE
INTAKE MANIFOLD VACUUM CHECK <6G7>
Refer to GROUP 11A - On-vehicle Service
AIR CLEANER
REMOVAL AND INSTALLATION
Caution
Parts marked by * are made of recycled-paper mixed plastic material, so observe the following
precautions.
1. Avoid any shock or load to these parts when removing and installing them.
2. Engage the case hinges securely when assembling these parts.
NOTE
Parts marked by * are made of recycled-paper mixed plastic material, so can be disposed of by incineration.
<6G7> <4D5, 4M4>
6
7* 3.9 ± 1.0 N×m
7*
4
3.9 ± 1.0 N×m
8
8
9*
9*
11
9.0 ± 1.0 N×m 9.0 ± 1.0 N×m 1
1 11
10 12
10
Removal steps
1. Air duct (A) 7. Air cleaner cover
2. Air duct (B) <6G7> 8. Air cleaner element
3. Pre-cleaner assembly <4D5, 4M4> 9. Air cleaner body
4. Air intake hose 10. Air cleaner bracket
5. Resonator <6G7> 11. Unloader valve
6. Air flow sensor assembly <6G7> 12. Unloader valve <4D5, 4M4>
INTAKE AND EXHAUST - Intercooler <4D5, 4M4> 15-5
INTERCOOLER <4D5, 4M4>
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Air Cleaner Removal and Installation (Refer to P.15-4) D Radiator Shroud Cover Removal and Installation
D Skid Plate and Under Cover Removal and Installation (Refer to GROUP 14.)
1
6.0 ± 1.0 N×m
9.0 ± 2.0 N×m
12 ± 2 N×m
12 ± 2 N×m
4
Removal steps
1. Intercooler air hose 4. Intercooler assembly
2. Intercooler air hose 5. Deflector plate
3. Intercooler air hose 6. Intercooler air pipe
INSPECTION
D Check the intercooler fins for bending damage or foreign
matter.
D Check the intercooler hoses for cracking, damage or wear.
15-6 INTAKE AND EXHAUST - Intake Manifold <6G7>
3 5
4 11 ± 1 N×m
2
11 1
17
6
10
9
8 7
5.0 ± 1.0 N×m
16
20
15
11 ± 1 N×m 22 21 9.0 ± 1.0 N×m 12
14
23 13
19 11 ± 1 N×m
14 ± 1 N×m
24
18
25
INTAKE AND EXHAUST - Intake Manifold <6G7> 15-7
Removal step 11. Throttle control servo connector
1. Ignition failure sensor connector 12. PCV hose and pipe assembly
2. Detonation sensor connector 13. PCV hose A
3. Throttle position sensor connector 14. PCV hose C
4. Control harness and injector harness 15. PCV hose B
connection 16. PCV pipe
5. Control harness and ignition coil 17. Fuel pipe clamp
harness connection 18. Water outlet fitting bracket
6. Control harness and fuel pressure sen- 19. Earth cable connection
sor harness and camshaft position 20. Ignition failure sensor
sensor harness connection 21. Vacuum hose
7. Purge solenoid valve connector 22. Purge hose
8. Crank angle sensor connector 23. Purge control solenoid valve
9. Water temperature gauge unit "AA 24. Intake manifold
10. Engine coolant temperature sensor 25. Intake manifold gasket
connector
INSPECTION
Check the following points; replace the part if a problem is
found.
19
10 6
9
21
11 18 20
17
12
22 ± 4 N×m
5 16
15 8
13
44 ± 8 N×m
4
31 ± 1 N×m
(Engine oil)
13 7 (Transmission fluid)
31 ± 1 N×m
2
3
6.0 ± 1.0 N×m 13 (Engine oil)
14
INTAKE AND EXHAUST - Intake Manifold and Throttle Body <4M4> 15-9
Removal steps
1. EGR valve and pipe assembly 11. Rocker cover gasket
2. Boost air temperature sensor 12. Intake manifold cover
connector 13. Clamp
3. Boost air temperature sensor 14. Injection pipe stay
4. Intake air fitting AA" "BA 15. Injection pipe
5. Throttle body assembly "BA 16. Injection pipe seal
6. Fuel hose connection 17. Gas filter assembly
7. Engine oil level gauge and guide "AA 18. Intake manifold
8. ATF level gauge and guide 19. Spacer A
9. Breather hose connection 20. Spacer B
10. Rocker cover 21. Intake manifold gasket
Nut
Delivery
holder
INSPECTION
INTAKE MANIFOLD CHECK
1. Check for damage or cracking of any part.
2. Clogging of the negative pressure (vacuum) outlet port,
or clogging of the gas passages.
3. Check distortion of installation surface with straight edge
and thickness gauge.
Standard value: 0.15 mm or less
Limit: 0.20 mm
INTAKE AND EXHAUST - Exhaust Manifold <6G7> 15-11
EXHAUST MANIFOLD <6G7>
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operations
D Engine Cover Removal And Installation D Skid Plate And Under Cover Removal And Installation
(Refer to GROUP 11A - Timing Belt) D Front Exhaust Pipe Removal And Installation (Refer
D Battery, Battery Tray Removal And Installation to P.15-21.)
D Air Cleaner Assembly Removal And Installation (Refer D Front Catalytic Converter Removal And Installation
to P.15-4.) (Refer to GROUP 17.)
2
1
59 ± 10 N×m 18 ± 2 N×m
14 ± 1 N×m
14 ± 1 N×m
14 ± 1 N×m
8
4
10
6
49 ± 5 N×m 5
9
49 ± 5 N×m
14 ± 1 N×m
(Engine oil)
Removal steps
1. EGR pipe 6. Exhaust manifold gasket
2. EGR pipe gasket 7. Engine oil level gauge and guide
3. Throttle body stay 8. Heat protector
4. Heat protector 9. Exhaust manifold
5. Exhaust manifold 10. Exhaust manifold gasket
INSPECTION
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 thickness gauge, check for
distortion of the cylinder head installation surface.
Standard value: 0.15 mm or less
Limit: 0.20 mm
Intake and Exhaust Manifold,
15-12 INTAKE AND EXHAUST - Turbocharger <4D5>
25 ± 4 N×m 18 ± 2 N×m
12 1
21
17 ± 2 N×m
59 ± 10 N×m 18 ± 2 N×m
7
11
20
6 6 ± 1 N×m
3
18 ± 2 N×m
14 ± 1 N×m
19
12 ± 1 N×m 11 ± 1 N×m
42 ± 7 N×m 14 8
13
17
5
18 16
3 18 ± 2 N×m
59 ± 10 N×m
42 ± 7 N×m
15
8.8 ± 1.0 N×m
10 22
9
8.8 ± 1.0 N×m
Removal steps
1. Air pipe 13. Exhaust manifold and turbocharger
2. Air intake hose assembly
3. Vacuum hose connection 14. Exhaust fitting heat protector
4. Turbocharger heat protector 15. Exhaust manifold heat protector
5. Water pipe (B) connection 16. Exhaust manifold
6. Waste gate actuator "AA 17. Turbocharger assembly
7. Oil pipe 18. Turbocharger gasket
8. Water pipe (A) 19. Exhaust fitting assembly
9. Oil return hose 20. Exhaust fitting gasket
10. Oil return pipe 21. Intake manifold
11. EGR pipe 22. Intake and exhaust manifold gasket
12. EGR valve
Intake and Exhaust Manifold,
INTAKE AND EXHAUST - Turbocharger <4D5> 15-13
INSTALLATION SERVICE POINT
"AA TURBOCHARGER ASSEMBLY INSTALLATION
1. Check the internal surface, the eye bolt and the
mating surface of the oil pipe and water pipe for
clogging, and clean if necessary.
2. If deposits of carbon are accumulated on the
turbocharger oil passage, remove them and clean
using the compressed air.
Caution
Be careful not to allow foreign material to enter the
turbocharger.
3. Add clean engine oil through the oil feed pipe port
on the turbocharger.
INSPECTION
TURBOCHARGER ASSEMBLY CHECK
D Visually check the turbine wheel and the compressor
wheel for cracking or other damage.
D Check whether the turbine wheel and the compressor
wheel can be easily turned by hand.
D Check for oil leakage from the turbocharger assembly.
D Check whether or not the waste gate valve remains open.
If any problem is found, replace the part after disassembly.
13 ± 1 N×m
30 ± 3 N×m
16
9
1
20 ± 2 N×m
25 ± 2 N×m 5 17
25 ± 2 N×m
20 ± 2 N×m
13 ± 1 N×m
13 ± 1 N×m
49 ± 4 N×m
3 2 13 ± 1 N×m
25 ± 2 N×m 4
3
13 ± 1 N×m
6 13 ± 1 N×m
Removal steps
1. EGR valve and pipe assembly 10. Turbocharger and exhaust fitting
2. Turbocharger cover assembly
3. Water pipe 11. Turbocharger cover
4. Turbocharger cover 12. Waste gate actuator
5. Oil pipe 13. Turbocharger cover
6. Oil return hose 14. Exhaust fitting
7. Oil return pipe "AA 15. Turbocharger assembly
8. Oil return pipe gasket 16. Exhaust manifold
9. Heat protector 17. Exhaust manifold gasket
INTAKE AND EXHAUST -
Turbocharger and Exhaust
Manifold <4M4>
15-15
INSTALLATION SERVICE POINT
"AA TURBOCHARGER ASSEMBLY INSTALLATION
1. Check the internal surface, the eye bolt and the
mating surface of the oil pipe and water pipe for
clogging, and clean if necessary.
2. If deposits of carbon are accumulated on the
turbocharger oil passage, remove them and clean
using the compressed air.
Caution
Be careful not to allow foreign material to enter the
turbocharger.
3. Add clean engine oil through the oil feed pipe port
on the turbocharger.
INSPECTION
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 thickness gauge, check for
distortion of the cylinder head installation surface.
Standard value: 0.15 mm or less
Limit: 0.20 mm
TURBOCHARGER <4D5>
DISASSEMBLY AND REASSEMBLY
5
6
5 N×m
Disassembly steps
"EA 1. Coupling
"DA 2. Turbine housing
AA" "CA 3. Snap ring
AB" "BA 4. Turbine wheel assembly
5. Compressor cover
"AA 6. O-ring
Turbine
wheel
assembly
CLEANING
1. Use a clean cleaning oil commercially available. Do not
use corrosive cleaning oils as they could damage to some
parts.
2. Use a plastic scraper or hard brush to clean aluminum
parts.
Coupling
COMPRESSOR COVER
Oil passage
Check the compressor cover for traces of contact with the
Turbine wheel compressor wheel and other damage.
TURBINE WHEEL ASSEMBLY
1. Check the turbine and compressor wheel blades for bend,
burr, damage, corrosion and traces of contact on the
back side and replace if defective.
Water passage 2. Check the oil passage of the turbine wheel assembly
Compressor
wheel for deposit and clogging.
3. In the case of water cooled type, check also the water
passage for deposit and clogging.
4. Check the turbine wheel and compressor wheel for light
and smooth turning.
3
8.3 N×m
5
6 8
7
4
*1
1
*2
Disassembly steps
1. Hose "AA 7. O-ring
2. Actuator 8. Cartridge assembly
3. Coupling
AA" 4. Turbine housing *1: Turbine wheel
"BA 5. Snap ring *2: Compressor wheel
AB" 6. Compressor cover
Compressor cover
15-20 INTAKE AND EXHAUST - Turbocharger <4M4>
CLEANING
TURBINE HOUSING/COMPRESSOR COVER
1. Prior to cleaning, visually check the disassembled parts
for evidences of burns, abrasions or other flaws because
they may become unrecognizable after washing. Replace
A
B if necessary.
C
2. Immerse the disassembled parts in the nonflammable
solvent A (DAI-CLEANER T-30 from Daido Chemical
Industry Co., Ltd.). Remove them from the solvent and
blow compressed air B against them.
Scrape off foreign matters, if any, using a plastic scraper
C before the immersion.
12
13 ± 2 N×m
9
7 7 8
49 ± 10 N×m
14 1
13 ± 2 N×m
<Short wheelbase>
19
14 4 13 ± 2 N×m
49 ± 10 N×m
15
44 ± 5 N×m 13 ± 2 N×m
6
17 14
49 ± 10 N×m
16
25 ± 4 N×m
20
49 ± 10 N×m 3
44 ± 5 N×m
18
49 ± 4 N×m 7
13 11
2
49 ± 10 N×m
<Long wheelbase>
14
13 ± 2 N×m
19
14 5
13 ± 2 N×m 10
49 ± 10 N×m 15 7
13 ± 2 N×m
44 ± 5 N×m
13 ± 2 N×m
6 17
14
16 49 ± 5 N×m
25 ± 4 N×m
49 ± 10 N×m 20 3
44 ± 5 N×m
18
49 ± 4 N×m
15-22 INTAKE AND EXHAUST - Exhaust Pipe and Main Muffler <6G7>
13 ± 2 N×m 11
8
6 6
7
49 ± 10 N×m
18
3 13 ± 2 N×m
49 ± 10 N×m
14
16
17 13 13 ± 2 N×m
15
13
49 ± 10 N×m
5
49 ± 4 N×m
19
25 ± 4 N×m
6
10
12
2
<Long wheelbase> 49 ± 10 N×m
13
13 ± 2 N×m
18 4
16 9
13
13 ± 2 N×m
6
14 13 ± 2 N×m
17
49 ± 10 N×m 13 ± 2 N×m
13
15 49 ± 10 N×m
5
19 49 ± 4 N×m
25 ± 4 N×m
15-24 INTAKE AND EXHAUST - Exhaust Pipe and Main Muffler <4D5>
Exhaust main muffler and rear Exhaust main muffler removal steps
floor heat protector removal steps <Long wheelbase>
<Short wheelbase> 4. Exhaust main muffler
1. Exhaust main muffler 13. Hanger
6. Hanger 14. Hanger bracket
7. Hanger bracket Front exhaust pipe and dash heat
8. Hanger bracket protector removal steps
11. Rear floor heat protector
D Under cover
Tail exhaust pipe and rear floor 5. Front exhaust pipe
heat protector removal steps 15. Exhaust support bracket
<Long wheelbase> 16. Dash heat protector
2. Tail exhaust pipe Pre-muffler and front floor heat
7. Hanger protector removal steps
9. Hanger bracket
10. Hanger bracket 17. Pre-muffler
12. Rear floor heat protector 18. Front floor heat protector
19. Seal ring
Center exhaust pipe removal steps
<Short wheelbase>
3. Center exhaust pipe
13. Hanger
14. Hanger bracket
INTAKE AND EXHAUST - Exhaust Pipe and Main Muffler <4M4> 15-25
EXHAUST PIPE AND MAIN MUFFLER <4M4>
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Front Under Cover Removal and Installation
11
13 ± 2 N×m
8
6
6 7
49 ± 10 N×m
13
<Short wheelbase> 1 13 ± 2 N×m
18
13 13 ± 2 N×m
49 ± 10 N×m 3
16 14
15 13 ± 2 N×m
5 13
49 ± 10 N×m
17
25 ± 4 N×m 19
6 10
49 ± 4 N×m
2 12
49 ± 10 N×m
<Long wheelbase>
13
13 ± 2 N×m
16 18
49 ± 10 N×m 13 4
13 ± 2 N×m 9
14 6
13 ± 2 N×m
15
13 ± 2 N×m
49 ± 10 N×m
13
5 17
25 ± 4 N×m 19
49 ± 4 N×m
15-26 INTAKE AND EXHAUST - Exhaust Pipe and Main Muffler<4M4>
Exhaust main muffler and rear Exhaust main muffler removal steps
floor heat protector removal steps <Long wheelbase>
<Short wheelbase> 4. Exhaust main muffler
1. Exhaust main muffler 13. Hanger
6. Hanger 14. Hanger bracket
7. Hanger bracket Front exhaust pipe and dash heat
8. Hanger bracket protector removal steps
11. Rear floor heat protector
D Under cover
Tail exhaust pipe and rear floor 5. Front exhaust pipe
heat protector removal steps 15. Exhaust support bracket
<Long wheelbase> 16. Dash heat protector
2. Tail exhaust pipe Front floor heat protector removal
7. Hanger steps
9. Hanger bracket
10. Hanger bracket 17. Catalytic converter
12. Rear floor heat protector 18. Front floor heat protector
19. Seal ring
Center exhaust pipe removal steps
<Short wheelbase>
3. Center exhaust pipe
13. Hanger
14. Hanger bracket
15-1
INTAKE AND
EXHAUST
CONTENTS
GENERAL
OUTLINE OF CHANGES
Some service procedures have been established as the following changes have been made due to the
compliance with the Emission Regulation Step III.
D An oxygen sensor (rear) has been added. Its service procedure is the same as for the previous
MT models <6G7-A/T>.
D The turbocharger has been changed to a Variable Geometry (VG) type <4D5>.
D A catalytic converter has been added <4D5>.
D The intake manifold has been reshaped <4M4>.
D An EGR cooler has been added <4M4>.
D The variable geometry turbocharger can not be disassembled, and must be always replaced as an
assembly.
GENERAL INFORMATION
The variable geometry solenoid valve is duty controlled to control the variable nozzle opening angle of the
variable geometry turbocharger. This allows to obtain the characteristic of boost pressure corresponding to
the engine operation status.
SERVICE SPECIFICATIONS
Items Standard value
SEALANT
Item Specified sealant Remarks
Thread of the intake manifold mounting 3M Stud Locking No.4170 or equivalent Anaerobic sealant
bolts
15-4 INTAKE AND EXHAUST - On-vehicle Service
ON-VEHICLE SERVICE
TURBOCHARGER SUPERCHARGING CHECK
Caution
Conduct the driving test in a location where driving at
full acceleration can be done with safety. Two person
should be in the vehicle when the test is conducted; the
person in the passenger seat should read the indications
shown by the MUT-II.
ON Approximately 80 Approximately 3
kPa kPa
NOTE
(1) If the variable geometry actuator vacuum is not in a normal
condition, the variable geometry actuator, variable
geometry solenoid valve, variable geometry control
pressure sensor, vacuum pump or hose may be faulty.
(2) If the variable geometry actuator vacuum is in a normal
condition but the supercharging pressure is not in a normal
condition, the variable geometry turbocharger nozzle,
boost pressure sensor, or hose may be faulty.
Caution
Be careful not to forcibly activate the variable geometry
solenoid valve to the fullest degree when running at a
high speed. Too much supercharging pressure could
damage the engine or the turbocharger.
15-6 INTAKE AND EXHAUST - On-vehicle Service
20
10
21
22
29 18
19
28
17 16
18 ± 2 N·m (Transmission fluid)
9
8 22 ± 4 N·m
27
15
7 5
26 13
6 15 ± 1 N·m
23 14
4 11
3 44 ± 8 N·m
1 12
2 3.0 ± 0.3 N·m
(Engine oil)
13 ± 1 N·m 25
(Engine oil)
23 ± 1 N·m 23 3.0 ± 0.3 N·m
29 ± 1 N·m
23
24
15-8 INTAKE AND EXHAUST - Intake Manifold and Throttle Body <4M4>
Removal steps
1. Intercooler air hose connection 15. Vacuum hose connection
2. Boost air temperature sensor 16. Intake manifold cover
connector 17. Air intake pipe stay
3. Boost air temperature sensor 18. Air intake pipe
4. Gasket 19. Air intake pipe gasket
5. Throttle motor connector 20. Breather hose connection
6. Intake air fitting 21. Rocker cover
7. O-ring 22. Rocker cover gasket
8. Throttle body assembly 23. Clamp
9. O-ring 24. Injection pipe stay
10. Fuel hose connection AA" "BA 25. Injection pipe
11. Engine oil level gauge and guide "BA 26. Injection pipe seal
12. O-ring 27. Gas filter assembly
13. ATF level gauge and guide "AA 28. Intake manifold
14. O-ring 29. Intake manifold gasket
Nut
Delivery
holder
18 ± 2 N·m
24 ± 4 N·m
2.5 ± 0.3 N·m
12
7 3 2.5 ± 0.3 N·m
11 13
10
14 ± 1 N·m
8
8
6
5 9
14 14 ± 1 N·m 2
8 18 ± 2 N·m
15 18 22 ± 4 N·m
16 17
24
6.0 ± 1.0 N·m 21 26 42 ± 7 N·m
31
33 14 ± 1
N·m 34
14 ± 1 N·m
23 32
28 30
27
12 ± 1 N·m
35 42 ± 7
N·m
29
14 ± 1 N·m
Intake and Exhaust Manifold, Throttle
INTAKE AND EXHAUST - Body and Turbocharger <4D5> 15-11
Removal steps
1. Dash panel heat protector 20. Gasket
2. Air pipe 21. Vacuum hose connection
3. Air intake hose 22. Intake manifold
4. Intercooler air hose 23. Exhaust manifold heat protector
5. Air temperature sensor connector 24. Water pipe A and water hose
6. Throttle solenoid valve connector assembly
7. VGT solenoid valve connector 25. Gasket
8. Vacuum hose connection 26. Water pipe B connection
9. Solenoid valve assembly 27. Gasket
10. Air temperature sensor 28. VG actuator
11. Gasket 29. Exhaust fitting heat protector
12. Earth cable connection 30. Front exhaust pipe connection
13. Air intake fitting 31. Gasket
14. Gasket 32. Oil return hose connection
15. Throttle body assembly 33. Exhaust manifold and turbocharger
16. Gasket assembly
17. Engine hanger 34. Intake and exhaust manifold gasket
18. Turbocharger upper heat protector 35. Oil return hose
19. Oil pipe assembly
40
38
39
59 ± 10 N·m
37
36
9.0 ± 1.0 N·m
13 ± 1 N·m
30 ± 3 N·m
15
8
20 ± 2 N·m
25 ± 2 N·m 4 16
25 ± 2 N·m
20 ± 2 N·m
13 ± 1 N·m
13 ± 1 N·m
49 ± 4 N·m
2 1 13 ± 1 N·m
25 ± 2 N·m
3
2
13 ± 1 N·m
5 13 ± 1 N·m
Removal steps
1. Turbocharger cover 10. Turbocharger cover
2. Water pipe 11. Waste gate actuator
3. Turbocharger cover 12. Turbocharger cover
4. Oil pipe 13. Exhaust fitting
5. Oil return hose "AA 14. Turbocharger assembly
6. Oil return pipe 15. Exhaust manifold
7. Oil return pipe gasket 16. Exhaust manifold gasket
8. Heat protector
9. Turbocharger and exhaust fitting
assembly
Turbocharger and Exhaust
INTAKE AND EXHAUST - Manifold <4M4>
15-13
INSTALLATION SERVICE POINT
"AA TURBOCHARGER ASSEMBLY INSTALLATION
1. Check the internal surface, the eye bolt and the
mating surface of the oil pipe and water pipe for
clogging, and clean if necessary.
2. If deposits of carbon are accumulated on the
turbocharger oil passage, remove them and clean
using the compressed air.
Caution
Be careful not to allow foreign material to enter the
turbocharger.
3. Add clean engine oil through the oil feed pipe port
on the turbocharger.
15-14 INTAKE AND EXHAUST - Exhaust Pipe and Main Muffler <4D5>
11
13 ± 2 N·m
8
6
6 7
49 ± 10 N·m
13 13 ± 2 N·m
<Short wheelbase> 1
18
49 ± 10 N·m 13 ± 2 N·m
3
16 14
13
13 ± 2 N·m
15 13
5 49 ± 10 N·m
17
19
25 ± 4 N·m
6
49 ± 4 N·m 10
12
2
49 ± 10 N·m
<Long wheelbase>
13
13 ± 2 N·m
4
18
16 49 ± 10 N·m 13 ± 2 N·m 9
13
6
14
13 ± 2 N·m
13 ± 2 N·m
15
13
49 ± 10 N·m
5
17
25 ± 4 N·m 19
49 ± 4 N·m
INTAKE AND EXHAUST - Exhaust Pipe and Main Muffler <4D5> 15-15
Exhaust main muffler and rear Exhaust main muffler removal steps
floor heat protector removal steps <Long wheelbase>
<Short wheelbase> 4. Exhaust main muffler
1. Exhaust main muffler 13. Hanger
6. Hanger 14. Hanger bracket
7. Hanger bracket Front exhaust pipe and dash heat
8. Hanger bracket protector removal steps
11. Rear floor heat protector
D Under cover
Tail exhaust pipe and rear floor 5. Front exhaust pipe
heat protector removal steps 15. Exhaust support bracket
<Long wheelbase> 16. Dash heat protector
2. Tail exhaust pipe Front floor heat protector removal
6. Hanger steps
9. Hanger bracket
10. Hanger bracket 17. Catalytic converter
12. Rear floor heat protector 18. Front floor heat protector
19. Seal ring
Center exhaust pipe removal steps
<Short wheelbase>
3. Center exhaust pipe
13. Hanger
14. Hanger bracket
15-1 INTAKE AND EXHAUST - General/Intake Manifold and Throttle Body <4M4>
GROUP 15
INTAKE AND EXHAUST
GENERAL
OUTLINE OF CHANGES
Due to the following changes, service procedures have been established. <4M4-engine vehicles complying
with Emission Regulation Step II>
D The intake manifold has been reshaped.
D The EGR pipe has been reshaped.
20
19 9
27 17
21 18
16
26 15
8
7 25
17 ± 2 N·m
12
6
14 13
4 15 ± 1 N·m 24
(A/T fluid)
5 22
22 ± 4 N·m
2 3
10 44 ± 8 N·m
14 ± 1 N·m (Engine oil)
6.0 ± 1.0 N·m 11 (Engine oil)
23 ± 1 N·m
1 23
29 ± 1 N·m 22
2.5 ± 0.5 N·m 2.5 ± 0.5 N·m
22
Removal steps
1. Intercooler air hose connection 14. Vacuum hose connection
2. Boost air temperature sensor 15. Intake manifold cover
connector 16. Air intake pipe stay
3. Boost air temperature sensor 17. Air intake pipe
4. Gasket 18. Air intake pipe gasket
5. Intake air fitting 19. Breather hose connection
6. O-ring 20. Rocker cover
7. Throttle body assembly 21. Rocker cover gasket
8. O-ring 22. Clamps
9. Fuel hose connections AA" "BA 23. Injection pipes
10. Engine oil level gauge and guide "BA 24. Injection pipe seals
11. O-ring 25. Gas filter assembly
12. A/T fluid level gauge and guide "AA 26. Intake manifold
13. O-ring 27. Intake manifold gasket
NOTE
The removal and installation service points are the same
as before.
15-3 INTAKE AND EXHAUST - Turbocharger and Exhaust Manifold <4M4>
13 ± 1 N·m
30 ± 3 N·m
10
18
19
20 ± 2 N·m
25 ± 2 N·m 20 ± 2 N·m
3 6 5
25 ± 2 N·m 6 13 ± 1 N·m
3
13 ± 1 N·m 49 ± 4 N·m
3
3
2 25 ± 2 N·m 1
4 13 ± 1 N·m
2
13 ± 1 N·m
17
15
6.0 ± 1.0 N·m
14
49 ± 4 N·m 16
9 11
13
8
12
4.9 ± 0.4 N·m
7 13 ± 1 N·m
Removal steps
1. Turbocharger cover 11. Turbocharger and exhaust fitting
2. Water pipes assembly
3. Gaskets 12. Turbocharger cover
4. Turbocharger cover 13. Waste gate actuator
5. Oil pipe 14. Turbocharger cover
6. Gaskets 15. Exhaust fitting
7. Oil return hose "AA 16. Turbocharger assembly
8. Oil return pipe 17. Turbocharger gaskets
9. Oil return pipe gasket 18. Exhaust manifold
10. Heat protector 19. Exhaust manifold gaskets
NOTE
The removal and installation service points are the same
as before.