II-I

INTAKE
CONTENTS
AIR FILTER EXHAUST EXHAUST GENERAL INTAKE .......................................................... MANIFOLD ....................................... ................... 4 11 13 2 6 SPECIFICATIONS ............................................... General Specifications .................................... Sealants and Adhesives .................................. Service Specifications ..................................... Torque Specifications ..................................... ........................................ TROUBLESHOOTING Abnormal Noise Exhaust Gas Leakage
Nl lAA-I;

2 2 3 2 3 4 . .

PIPES AND MUFFLERS INFORMATION MANIFOLD

.................................

...........................................

11-2

INTAKE AND EXHAUST

- General

Information

/ Specifications
NllBAAD

GENERAL INFORMATION

Air filter is a dry type air filter. The intake manifold, made of cast aluminum, functions to circulate engine coolant to the heat-riser (located at the carburetor installation part) and to facilitate the atomization of the air/fuel mixture. There are also passages for jet air and EGR (exhaust gas recirculation), and a thermostat housing is provided near the no. 1 port. The exhaust system is a single consisting of four divisions: the front exhaust pipe, the under catalytic converter, the center exhaust pipe, and the main muffler.

The exhaust

manifold,

made of cast metal,

is the dual type, and functions

to reduce exhaust

interference.

:!; SPECIFICATIONS
i GENERAL SPECIFICATIONS
items Air filter Type Heated air intake Exhaust system Front exhaust Muffler Coupling Suspension system pipe Dual type Expansion resonance type Dry type Vacuum motor type Specifications
NllCA-

Spherical coupling Rubber hangers and suspenders

SERVICE SPECIFICATIONS
Items Standard value Intake and exhaust manifold surface distortion mm (in.) 0.15 (.006) or less Cylinder head installation Limit Intake and exhaust manifold surface distortion mm (in.) 0.3 (.012) or less Cylinder head installation Specifications

( STB Revision

INTAKE AND EXHAUST TORQUE SPECIFICATIONS

Items Air filter to rocker cover Carburetor to intake manifold Intake manifold to cylinder head Water outlet fitting assembly to intake manifold Therm0 valve assembly to intake manifold E.G.R. valve assembly to intake manifold Vacuum connector joint Air pipe assembly to bracket Air pipe assembly to reed valve 6 bracket Therm0 switch to intake manifold Watertemperature gauge unit to intake manifold Water temperature sensor to intake manifold Joint to intake manifold Exhaust manifold cover to exhaust manifold Air pipe assembly to exhaust manifold Exhaust manifold to cylinder head Exhaust manifold to front exhaust pipe Front exhaust pipe to exhaust pipe mounting bracket Front exhaust pipe to under catalytic converter Under catalytic converter to center exhaust pipe Hanger bracket to suspender Suspender to frame Center exhaust pipe to main muffler Main muffler to hanger Hanger to frame Oxygen sensor

- Specifications

11-3
NllCC--

Nm 16-19
15-20 15-20 IO-13 20-40

ft.lbs.
12-14 11-14 11-14 7-9 14-29 14-20 6-9 9-l 1 7-9 4-7 6-7 14-29 14-29 9-11 51-72 11-14 14-22 14-22 11-18 29-43 6-9 6-9 14-22 4-7 4-7 29-36

19-28
8-12 12-15 IO-13

6-9
8-10 20-40 20-40 12-15 70-100 15-20 20-30 20-30 15-25 40-60 8-12 8-12 20-30 5-10 5-10 40-50

SEALANTS

AND ADHESIVES
Items Specified sealant and adhesive 3M Adhesive Nut Locking 4171 or equivalent 3M Adhesive Nut Locking 4171 or equivalent 3M Adhesive Nut Locking 4171 or equivalent 3M Adhesive Nut Locking 4171 or equivalent 3M Adhesive Nut Locking 4171 or equivalent 3M AdhesiveNut locking 4171 or equivalent Quantity As required As required As required As required As required As required

Nl lCD-

Therm0 switch (threaded part) Water temperature gauge unit (threaded part) Water temperature sensor . (threaded part) Therm0 valve assembly (threaded part) Joint (threaded part) Water temperature switch (threaded part)

( ST6 Revision

11-4
r

INTAKE AND EXHAUST

-Troubleshooting

/ Air Filter
NllEAAA

TROUBLESHOOTING
Symptom Exhaust gas leakage Probable cause Loose joints Broken pipe or muffler Abnormal noise Broken separator in muffler Remedy Retighten Repair or replace Replace Replace Correct Repair or replace

Reference we II-13 11-13 11-13 11-13 11-13 II-13

Broken rubber hangers or suspender Interference body of pipe or muffler with vehicle

Broken pipe or muffler

; AIR FILTER
,j REMOVAL AND INSTALLATION
NllFA-

Removal
1. 2. 3. 4. 5. 6. 7. 8. Wing nut Connection of breather hose Air duct Connection of air hose Air filter mounting nut Heat duct Connection of vacuum hose Air filter

NOTE (1) Reverse the removal procedures to reinstall. (2) l + : Refer to Service Point of Installation

SERVICE
2.

POINT

OF INSTALLATION
OF BREATHER
installing,

NllFDAA

INSTALLATION
NOTE Be careful, when

HOSE
oil etc. to the hose.

not to apply

1 STB Revision

INTAKE DISASSEMBLY AND REASSEMBLY

AND EXHAUST

- Air

Filter

II-5
NllFEAA

6
Disassembly
I. 2. 3. 4. 5. 6.

steps
Air filter Air filter Secondary Secondary Air filter Air filter cover element air case air filter gasket body procedures to reassemble.

NOTE (1) Reverse the disassembly (2) q : Non-reusable parts

i. -:

1 ST6 Revision

11-6 INTAKE MANIFOLD

REMOVAL

INTAKE

AND

EXHAUST

- Ontake Manifold

AND INSTALLATION
Post-installation Operation 0 Supplying of Coolant (Refer to GROUP 0 LUBRICATION AND MAINTENANCE - Maintenance Service.) l Checking and adjustment of idling rpm and ignition timing (Refer to GROUP 9 ENGINE - Service Adjustment Procedures.)

Pre-removal Operation Draining of coolant (Refer to GROUP 0 LUBRICATION AND MAINTENANCE - Maintenance vice.)

Ser-

16-19 Nm 12-14 ft.lbs. \

15-20 Nm 1 I-14 ft.lbs

15-20 Nm 1 l-14 ftlbs ,,,i 1 l-14 i ft.lbs. 1

12

04W569

Removal steps
+e +I) e+ e+ Air filter Carburetor Gasket Connection Connection Water hose Connection Connection hose 9. Connection 10. Connection connector tioner) 1. 2. 3. 4. 5. 6. 7. 8. assembly of radiator upper of water by-pass of heater of brake hose booster hose hose 11. Connection of connector 12. Connection of unit connector 13. Connection of (Vehicles with 14. Intake manifold 15. Intake manifold water water temperature temperature sensor gauge

therm0 switch connector an automatic transmission) gasket

vacuum

of vacuum hose of water temperature switch (Vehicles with an air condi-

NOTE (1) Reverse the removal procedures to reinstall. (2) +e : Refer to Service Points of Removal. (3) l + : Refer to Service Points of installation (4) q : Non-reusable parts

1 STB Revision

INTAKE

AND

EXHAUST SERVICE
1. REMOVAL

- Intake

Manifold

11-7
NllMBAD

POINTS
OF AIR

OF REMOVAL
FILTER

Refer to P.l l-4. 2. REMOVAL OF CARBURETOR ASSEMBLY Refer to GROUP 14 FUEL SYSTEM - Carburetor.

INSPECT10
Check found. INTAKE the following points; replace

NllMCAD

the part if a problem

is

;z i

MANIFOLD

(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 a thickness gage, check for distortion of the cylinder head installation surface. Standard value : 0.15 mm (.006 in.) or less Limit : 0.3 mm (.012 in.) or less

SERVICE
2.

POINTS

OF INSTALLATION

NllMDAC

INSTALLATION OF CARBURETOR ASSEMBLY Refer to GROUP 14 FUEL SYSTEM - Carburetor. OF AIR FILTER

5 I

1. INSiALLATlON Refer to P.l l-4.

1 STB Revision

11-8
DISASSEMBLY AND

INTAKE

AND

EXHAUST

- Intake

Manifold
NllME--

REASSEMBLY

8-9 Nm 5-6 ft.lbs. IO-13 Nm 7-9 ftlbs. 10-14 Nm 7-10 ftlbs. / 20-40 14-29 Nm ftlbs.

,----

8-12 Nm 8-9 ft.lbs.

14-29 ftlbs.

14-20 ftlbs. 8-10 Nm 6-7 ftlbs.

04W567

Disassembly steps l +
1. Water temperature switch (Vehicles with an air conditioner) 2. Plug (Vehicles without an air conditioner) 3. Joint 4. Engine hanger 5. Vacuum hose assembly 6. Joint 7. Therm0 valve assembly 8. Water temperature sensor 9. Water temperature gauge unit 10. P.C.V. nipple 11. Therm0 switch (Vehicles with an automatic transmission)

l +

l l l l
+4

+ + + +

l +

12. 13. 14. 15. 16. 17.

EGR valve assembly EGR valve gasket Water outlet fitting Gasket Thermostat Intake manifold the disassembly

assembly

NOTE (1) Reverse

(2) (3)

procedures
Points of

to reassemble.
Reassembly.

l
m

: Refer to Service : Non-reusable parts

1 STB Revision

INTAKE

AND EXHAUST SERVICE

- Intake

Manifold

11-9
NllMHAB

POINTS

OF REASSEMBLY
OF THERMOSTAT 7 COOLING -Thermostat

16. INSTALLATION Refer to GROUP

Il.

APPLICATION

OF ADHESIVE

TO THERM0

SWITCH

Apply a coating of the specified adhesive to the threaded part, and then tighten at the specified torque. Specified adhesive : 3M Adhesive equivalent Nut Locking 4171 or

04W563

9.

APPLICATION TURE GAUGE Apply a coating part, and then Specified

OF ADHESIVE TO WATER TEMPERAUNIT of the specified adhesive to the threaded tighten at the specified torque. : 3M Adhesive equivalent Nut Locking 4171 or

adhesive

04w550

8. APPLICATION OF ADHESIVE TO WATER TEMPERATURE SENSOR Apply a coating of the specified adhesive to the threaded part, and then tighten at the specified torque. Specified adhesive : 3M Adhesive equivalent Nut Locking 4171 or

1: : * I

04w559

7. APPLICATION OF SEALANT TO THERM0 VALVE ASSEMBLY Apply a coating of the specified adhesive to the threaded part, and then tighten at the specified torque. Specified adhesive : 3M Adhesive equivalent Nut Locking 4171 or

04W564

j STB Revision

II-10

INTAKE

AND

EXHAUST

- Intake

Manifold
TO JOINT

6. APPLICATION

OF ADHESIVE

Apply a coating of the specified adhesive to the threaded Part, and then tighten at the specified torque. Specified adhesive : 3M Adhesive equivalent Nut Locking 4171 or

04W562

3. APPLICATION OF ADHESIVE TO JOINT Apply a coating of the specified adhesive to the threaded part, and then tighten at the specified torque. Specified adhesive : 3M Adhesive equivalent Nut Locking 4171 or

1. APPLICATION TURE SWITCH Apply a coating part, and then Specified

OF ADHESIVE

TO

WATER

TEMPERA-

of the specified adhesive to the threaded tighten at the specified torque. : 3M Adhesive equivalent Nut Locking 4171 or

adhesive

04W.560

STB Revision

INTAKE

AND EXHAUST

- Exhaust

Manifold

II-II

EXHAUST
REMOVAL

MANIFOLD
AND INSTALLATION
NllNA-

16-19 Nm 12-14 ft.lbs. 10-13 Nm j-9 ftlbs.

12-15 Nm

15-20 klm 11-14 ft.lbs. 40-50 29-36 Nm ftlbs. \ -

/ 80

Removal steps
+e

04W566

l +

I. 2. 3. 4. 5.
6.

Air filter Air duct Heat duct Air pipe assembly Reed valve B bracket
Exhaust manifold cover

10. 11. 12. 13.

Gasket Engine Exhaust Exhaust

hanger manifold manifold

gasket 4
,\

7. Oxygen sensor 8. Self-locking nut 9. Connection of exhaust front exhaust pipe

manifold

and

NOTE (1) Reverse the removal procedures (2) l * : Refer to Service Points (3) l + : Refer to Service Points (4) : Non-reusable parts

to reinstall. of Removal. of Installation.

/ STB Revision

11-12

INTAKE

AND EXHAUST SERVICE

- Exhaust

Manifold

POINTS

OF REMOVAL

NllNBAA

1. REMOVAL OF AIR FILTER Refer to P.l l-4.

INSPECTION
Check found. the following points; replace

NllNdAD

the part if a problem

is

EXHAUST MANIFOLD (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 a thickness gauge, check for distortion of the cylinder head installation surface. Standard value : 0.15 mm (.006 in.) or less Limit : 0.3 mm (.OlZ in.) or less EXHAUST Check MANIFOLD GASKET of the gasket.

for flaking

or damage

SERVICE
1.

POINTS

OF INSTALLATION
OF AIR FILTER

NllNDAB

INSTALLATION Refer to P.ll-4.

1 STB Revision

INTAKE

AND

EXHAUST

- Exhaust

Pipes and Mufflers

II-13
N1lRA--

EXHAUST
REMOVAL

PIPES AND MUFFLERS

AND INSTALLATION

40-60 29-43 -22 ftlbs. -30 Nm 8-12 Nm

Nm ftlbs.

5-10 Nm 4-7 ft.lbs.

15-22 ftlbs.

15-25 11-18

iO0

io

8-l> ft.lbs. 6-9 Nm

Nm ft.lbs.

\ 20-30 Nm 15-22 ft.lbs.

05W521

:
,

* I

l +

~~ ~~

l +

1. 2. 3. 4. 5. 6. 7. 8. 9. IO.

Gasket Front exhaust pipe Spring Suspender Hanger bracket Center exhaust pipe Hanger Main muffler Catalytic converter assembly Self-locking nut

NOTE (1) l + : Refer to Service Points of Installation (2) q : Non-reusable parts

1 STB Revision

II-14

INTAKE

AND

EXHAUST

- Exhaust Pipes

and

Mufflers
NllRCAE

INSPECTION

@ Check the mufflers or pipes for corrosion or damage. l Check the rubber hangers or suspenders for deterioration or damage. l Check for gas leakage from mufflers or pipes.

SERVICE

POINTS

OF INSTALLATION

NllRDAE

2. INSTALLATION OF FRONT EXHAUST PIPE/G. CENTER EXHAUST PIW8. MAIN MUFFLER /9. CATALYTIC CONVERTER ASSEMBLY (1) Temporarily install the front exhaust pipe, the catalytic converter assembly, the center exhaust pipe, and the main muffler in that order. Caution With temporarily tightened, no distortion of the hangers. check to be sure there is

(2) After fully tightening each exhaust pipe and main muffler, check to be sure there is no contact with the chassis at any place.

STB Revision