Main

Index
GROUP 15

INTAKE AND
EXHAUST
CONTENTS

GENERAL INFORMATION . . . . . . . . 15-2 INTERCOOLER . . . . . . . . . . . . . . . . . 15-8

REMOVAL AND INSTALLATION <4G1> . . 15-8
SERVICE SPECIFICATIONS. . . . . . . 15-2
INLET MANIFOLD . . . . . . . . . . . . . . . 15-11
SPECIAL TOOL . . . . . . . . . . . . . . . . . 15-2 REMOVAL AND INSTALLTION <4A9>. . . . 15-11
REMOVAL AND INSTALLTION <4G1> . . . 15-12
ON-VEHICLE SERVICE. . . . . . . . . . . 15-3 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 15-13
TURBOCHARGER SUPERCHARGING
PRESSURE CHECK <4G1>. . . . . . . . . . . . 15-3 EXHAUST MANIFOLD . . . . . . . . . . . . 15-14
SUPERCHARGING PRESSURE REMOVAL AND INSTALLATION <4A9> . . 15-14
CONTROL SYSTEM CHECK <4G1> . . . . . 15-3
INSPECTION <4A9> . . . . . . . . . . . . . . . . . . 15-14
WASTE GATE ACTUATOR CHECK
<4G1> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4
EXHAUST MANIFOLD AND
WASTE GATE SOLENOID VALVE CHECK
<4G1> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4 TURBOCHARGER . . . . . . . . . . . . . . . 15-15
AIR BY-PASS VALVE CHECK <4G1> . . . . 15-4 REMOVAL AND INSTALLATION <4G1> . . 15-15
INTAKE MANIFOLD VACUUM CHECK . . . 15-4 INSPECTION <4G1>. . . . . . . . . . . . . . . . . . 15-18

AIR CLEANER . . . . . . . . . . . . . . . . . . 15-5 EXHAUST PIPE AND MAIN

REMOVAL AND INSTALLATION <4A9> . . 15-5
MUFFLER . . . . . . . . . . . . . . . . . . . . . . 15-19
REMOVAL AND INSTALLATION <4G1> . . 15-6 REMOVAL AND INSTALLATION <4A9> . . 15-19
REMOVAL AND INSTALLATION <4G1> . . 15-21
15-2 INTAKE AND EXHAUST
GENERAL INFORMATION

GENERAL INFORMATION Main

Index
M1151000100703
The exhaust pipe is divided into three parts.
Group
TOC
SERVICE SPECIFICATIONS
M1151000300848

Item Standard value Limit

Turbocharger supercharging pressure (waste gate 39 − 65 −
solenoid valve not operating) kPa
Initial activation pressure of waste gate actuator (at the 60 −
stroke of approxim ately 1mm) kPa
Waste gate solenoid valve coil resistance (at 20°C) Ω 29 − 35 −
Initial activation pressure of air by pass valve kPa Approximately 53 −
Manifold distortion of the installation surface mm 0.15 or less 0.20

SPECIAL TOOL
M1151000600623

Tool Number Name Use

MB991953 Oxygen sensor Removal and installation of oxygen
wrench sensor

B991953
 INTAKE AND EXHAUST
ON-VEHICLE SERVICE
15-3
ON-VEHICLE SERVICE Main
Index
TURBOCHARGER SUPERCHARGING SUPERCHARGING PRESSURE
PRESSURE CHECK <4G1> CONTROL SYSTEM CHECK <4G1>
M1151001000356 M1151001100267 Group
CAUTION TOC
Two persons should be in the vehicle when the Three-way joint
test is conducted; the person in the passenger
seat should read the indications shown by the
pressure meter.

Turbocharger waste
gate solenoid valve
AK402050 AC

1. Disconnect the hose (white paint mark) from the

Plug turbocharger waste gate solenoid valve and
Turbocharger waste connect a three-way joint between the hose and
gate solenoid valve the solenoid valve.
AK402049AC
2. Connect a hand vacuum pump to the three-way
1. Disconnect the hose (white paint mark) from the joint.
turbocharger waste gate solenoid valve, and
connect the pressure gauge to the hose. Plug the Nipple
nipple of the solenoid valve from which the hose
(white paint mark) has been disconnected.
2. Drive at full-throttle acceleration in second gear
and then measure the supercharging pressure
when the engine speed in about 3,000 r/min.
Boost hose (Red stripe)
Standard value: 39 − 65 kPa
3. If the supercharging pressure deviates from the
AK402051AC
standard value, check the following items for
possible cause. 3. Disconnect the hose from the turbocharger waste
• Malfunction of the waste gate actuator gate actuator control boost nipple and plug the
• Leakage of supercharging pressure nipple.
• Malfunction of the turbocharger
4. Applying a negative pressure with the hand
4. When the indicated supercharging is more than vacuum pump, check tightness both when the
standard value, supercharging control may be hose end is closed and when it is open.
faulty, therefore check the followings.
• Malfunction of the waste gate actuator Engine state Hose end Normal state
• Malfunction of waste gate valve Stop Opened Negative
• Disconnection or cracks of the waste gate actua- (Ignition switch: ON) pressure leaks.
tor rubber hose Closed Negative
pressure is
maintained.
Idling (after Negative
warm-up) pressure leaks.
NOTE: If this check indicates an abnormal condi-
tion; the turbocharger waste gate actuator, turbo-
charger waste gate solenoid or hose is broken.
15-4 INTAKE AND EXHAUST
ON-VEHICLE SERVICE

WASTE GATE ACTUATOR CHECK <4G1> Jumper wire B nipple Normal condition
Main
M1151001200297
condition Index
Connected Opened Negative pressure leaks.
Closed Negative pressure is Group
held. TOC
Disconnected Opened Negative pressure is
held.

COIL RESISTANCE CHECK

AK402022

1. Connect a manual pump (pressure-application

type) to nipple.
CAUTION
In order to avoid damage to the diaphragm, do
not apply a pressure of 75 kPa or higher.
2. While gradually applying pressure, check the
pressure that begins to activate (approximately 1 AK200442
mm stroke) the waste gate actuator rod.
Measure the resistance between solenoid valve ter-
Standard value: Approximately 60 kPa minals
3. If there is a significant deviation from the standard Standard value: 29 − 35 Ω (at 20°C)
value, check the actuator or the waste gate valve:
replace actuator or turbocharger assembly if AIR BY-PASS VALVE CHECK <4G1>
M1151001600165
necessary.

WASTE GATE SOLENOID VALVE CHECK

<4G1>
M1151001300205

OPERATION CHECK
A
B

AK200443

1. Remove the air bypass valve.

2. Connect the hand vacuum pump to the nipple of
the air bypass valve.
Battery 3. Apply a negative pressure of approximately 93
AK200441AC kPa, and check that air tightness is maintained.
1. Connect a hand vacuum pump to the solenoid 4. Also check operation of the valve.
valve nipple A. Standard value:
2. Using a jumper wire, connect between the Negative pressure Valve operation
solenoid valve terminal and battery terminal.
Approximately 53 kPa It starts opening
3. Connecting and disconnecting the jumper wire at
the battery negative terminal to apply a negative INTAKE MANIFOLD VACUUM CHECK
pressure, check tightness. M1151001800266
Refer to GROUP 11A − On-vehicle Service
P.11A-13. <4A9>
Refer to GROUP 11C − On-vehicle Service
P.11C-14. <4G1>
 INTAKE AND EXHAUST
AIR CLEANER
15-5
AIR CLEANER Main
Index
REMOVAL AND INSTALLATION <4A9>
M1151002101177

Group
TOC
4.0 ± 1.0 N·m

8
2
<M/T>
4.0 ± 1.0 N·m

4.0 ± 1.0 N·m 8

9 3

4.0 ± 1.0 N·m

10 9.0 ± 1.0 N·m
4
5
<CVT>
7
9.0 ± 1.0 N·m 6

7
1

AC601194AB

Removal steps Removal steps (Continued)

1. Air cleaner intake duct 6. Air cleaner body assembly
2. Air cleaner cover 7. Clip
3. Air cleaner element 8. Breather hose connection
4. Fuel vapour control hose 9. Engine air intake hose <M/T>
5. Breather hose 10. Engine air intake hose <CVT>
15-6 INTAKE AND EXHAUST
AIR CLEANER

REMOVAL AND INSTALLATION <4G1> Main

M1151002101315 Index
1.8 ± 0.6 N·m

Group
4 TOC
3 2

5
4.0 ± 1.0 N·m

10
6
4.0 ± 1.0 N·m

6.0 ± 1.0 N·m 12

11 9.0 ± 1.0 N·m 9.0 ± 1.0 N·m

7 8

9
13

4.0 ± 1.0 N·m

1

AC600110AB

Removal steps Removal steps (Continued)

1. Air cleaner intake duct 7. Breather hose
2. Air cleaner air flow sensor 8. Air cleaner body assembly
connector 9. Clip
3. Air cleaner air flow sensor, air 10. Engine air intake hose
cleaner cover assembly 11. Breather hose connection
4. Air cleaner air flow sensor >>B<< 12. Air by-pass valve connection
5. Air cleaner cover >>A<< 13. Engine air intake hose
6. Air cleaner element
 INTAKE AND EXHAUST
AIR CLEANER
15-7
INSTALLATION SERVICE POINTS Main
>>A<< ENGINE AIR INTAKE HOSE >>B<< AIR BY-PASS VALVE Index
INSTALLATION CONNECTION
Air by-pass valve Group
Engine TOC
air intake hose
Mating mark
Mating mark (white)
(green)

Nipple Mating mark

Turbocharger
assembly Engine
air intake hose AC600112AB
AC600111AE

Install by aligning the mating mark (green) on the Install by aligning the mating mark (white) on the air
engine air intake hose with the nipple on the turbo- by-pass valve and the mating mark on the engine air
charger assembly. intake hose.
15-8 INTAKE AND EXHAUST
INTERCOOLER

INTERCOOLER Main
Index
REMOVAL AND INSTALLATION <4G1>
M1151004200188

6.0 ± 1.0 N·m

Group
6.0 ± 1.0 N·m TOC
4

6.0 ± 1.0 N·m

3 6.0 ± 1.0 N·m

2 24 ± 4 N·m
5

5.0 ± 1.0 N·m

6
10 ± 1 N·m
6.0 ± 1.0 N·m

6.0 ± 1.0 N·m

11 N 7
8 11 ± 2 N·m
10
6.0 ± 1.0 N·m
18
20 ± 4 N·m 5.4 ± 1.0 N·m
5.4 ± 1.0 N·m

6.0 ± 1.0 N·m 17 19

9 7.5 ± 1.0 N·m

5.4 ± 1.0 N·m 15 N

6.0 ± 1.0 N·m 11 ± 2 N·m

11 ± 2 N·m
20
16 14 13
5.4 ± 1.0 N·m
12
AC600078 AB

Removal steps Removal steps (Continued)

>>H<< 1. Air hose C • Air cleaner assembly (Refer to
>>G<< 2. Air by-pass hose P.15-6)
>>F<< 3. Air by-pass valve >>E<< 4. Air pipe B
>>D<< 5. Air hose D
 INTAKE AND EXHAUST
INTERCOOLER
15-9
Removal steps (Continued) Main
>>C<< 6. Air pipe A >>B<<AIR HOSE B INSTALLATION Index
7. Bracket
>>B<< 8. Air hose B Air hose B
>>A<< 9. Air hose A Group
10. Air outlet fitting TOC
11. Gasket Mating mark
• Front bumper assembly (Refer to (yellow)
GROUP 51 − Front Bumper
Assembly, Radiator Grille P.51-2). Mating mark
• Side under cover (LH) Intercooler
12. Intercooler assembly, intercooler air pipe
inlet air duct, intercooler air pipe
AC402295AC
13. Intercooler assembly AC402295

14. Intercooler air pipe

15. O-ring Install by aligning the mating mark (yellow) on air
16. Intercooler inlet air duct hose B and the mating mark on the intercooler air
17. Bracket pipe.
18. Bracket
19. Intercooler baffle plate
>>C<<AIR PIPE A INSTALLATION
20. Bracket

INSTALLATION SERVICE POINTS Mating mark Air pipe A

>>A<<AIR HOSE A INSTALLATION (white)

Air hose A
Air hose B
Mating mark (green) AC600076AB

Install by aligning the mating marks (white) on air

Mating mark pipe A and on air hose B.
Intercooler assembly
(inlet side) AC402293AG
AC402293
>>D<<AIR HOSE D INSTALLATION
1. Install by aligning the mating mark (green) on air Projection Air hose D
hose A and the mating mark on the intercooler Throttle body
assembly (inlet side).
Air outlet fitting Mating mark
(white)

Mating mark
(yellow)
AC600077AB

Install by aligning the mating mark (white) on air

hose D and the projection on the throttle body.
Air hose A
AC402297AB

2. Install by aligning the mating marks (yellow) on air

hose A and on the air outlet fitting.
15-10 INTAKE AND EXHAUST
INTERCOOLER

>>E<<AIR PIPE B INSTALLATION Mating mark (white)

Main
Air by-pass hose
Index
Air hose D Rib

Group
TOC

Mating mark 4 mm
(yellow) (yellow line)
Air by-pass valve
Air pipe B AC402291AB
AC402291

AC402294AB
AC402294
2. Install by aligning the mating mark (white) on the
1. Align the end of air hose D so that the width of the air by-pass hose and the centre of the air by-pass
yellow line on air pipe B should be 4 mm. valve rib.
2. Install by aligning the mating marks (yellow) on air
pipe B and on air hose D. >>H<<AIR HOSE C INSTALLATION
Air hose C Mating mark
>>F<<AIR BY-PASS VALVE (yellow)
Air pipe B

INSTALLATION
Air by-pass valve

Mating mark
(white)

Mating mark

AC402296AG
Engine
air intake hose AC600112AB 1. Install by aligning the mating marks (yellow) on air
Install by aligning the mating mark (white) on the air hose C and on air pipe B.
by-pass valve and the mating mark on the engine air Air hose C Mating mark
intake hose. (green)
Mating mark
>>G<<AIR BY-PASS HOSE (white)

INSTALLATION
Air pipe B
Mating mark
Air pipe A

AC402292AE

2. Install by aligning the mating mark (green) on the

air hose C and the mating mark (white) on the air
pipe A.
Mating mark
(green)

Air by-pass hose AC402296AH

1. Install by aligning the mating mark (green) on the

air by-pass hose and the mating mark on air pipe
B.
 INTAKE AND EXHAUST
INLET MANIFOLD
15-11
INLET MANIFOLD Main
Index
REMOVAL AND INSTALLTION <4A9>
M1151003001816

Pre-removal Operation Post-installation Operation Group

• Engine Coolant Draining (Refer to GROUP 14, On-vehicle
Service − Engine Coolant Replacement P.14-4).
• Air Cleaner Assembly, Air Intake Duct Removal (Refer to
P.15-5).
• Throttle Body Removal (Refer to GROUP 13A, Throttle
Body P.13A-370).
• Fuel Injector Removal (Refer to Group 13A, Injector
P.13A-367).
• EGR Valve Assembly Removal <CVT> (Refer to GROUP
17, EGR Valve P.17-22).
• EGR Valve Assembly Installation <CVT> (Refer to TOC
GROUP 17, EGR Valve P.17-22).
• Fuel Injector Installation (Refer to GROUP 13A, Injector
P.13A-367).
• Throttle Body Installation (Refer to GROUP 13A, Throttle
Body P.13A-370).
• Air Cleaner Assembly, Air Intake Duct Installation (Refer
to P.15-5).
• Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
Service − Engine Coolant Replacement P.14-4).

1
6.0 ± 0.5 N·m
8
7
9
14 ± 3 N·m
6
18 ± 1 N·m
2
3 5
N 14

15
11 ± 1 N·m
4
13
10 18 ± 1 N·m

12
11
AC601295AB

Removal steps Removal steps (Continued)

1. Harness clamp connection >>A<< 8. Screw
2. Alternator connector 9. Manifold absolute pressure sensor
3. Alternator terminal 10. Harness clamp connection
4. PCV hose connection 11. Harness clamp connection <M/T>
5. Brake booster vacuum hose 12. Inlet manifold stay <M/T>
connection <M/T> 13. Inlet manifold
6. Purge hose connection <M/T> 14. Inlet manifold gasket
7. Manifold absolute pressure sensor 15. Ball stud
connector
15-12 INTAKE AND EXHAUST
INLET MANIFOLD

INSTALLATION SERVICE POINT REMOVAL AND INSTALLTION <4G1> Main

>>A<< SCREW INSTALLATION
M1151003001838 Index
CAUTION
Do not over-tighten. As the self-forming-type Group
screw is used, the excessive torque can damage TOC
the inlet manifold threads.
Pre-removal Operation Post-installation Operation
• Cowl Top Panel Removal (Refer to GROUP42, Loose • Fuel Injector Installation (Refer to GROUP 13B, Injector
Panel P.42-81). P.13B-370).
• Engine Coolant Draining (Refer to GROUP14, On-vehicle • Throttle Body Installation (Refer to GROUP 13B, Throttle
Service − Engine Coolant Replacement P.14-6). Body Assembly P.13B-373).
• Air Cleaner Assembly, Air Intake Duct Removal (Refer to • Air Hose C, Air Pipe B, Air Hose D Installation (Refer to
P.15-6). P.15-8).
• Air Hose C, Air Pipe B, Air Hose D Removal (Refer to • Air Cleaner Assembly, Air Intake Duct Installation (Refer
P.15-8). to P.15-6).
• Throttle Body Removal (Refer to GROUP 13B, Throttle • Engine Coolant Refilling (Refer to GROUP14, On-vehicle
Body Assembly P.13B-373). Service − Engine Coolant Replacement P.14-6).
• Fuel Injector Removal (Refer to GROUP 13B, Injector • Cowl Top Panel Installation (Refer to GROUP42, Loose
P.13B-370). Panel P.42-81).

5.0 ± 1.0 N·m 3 7

1
N5 6
9.0 ± 1.0 N·m
10 4
9
8
14
2
18 ± 2 N·m
18 ± 2 N·m

13

31 ± 3 N·m N 15
18 ± 2 N·m

48 ± 2 N·m
11

48 ± 6 N·m

12

24 ± 4 N·m AC405187AB
 INTAKE AND EXHAUST
INLET MANIFOLD
15-13
Removal steps Removal steps (Continued) Main
1. Purge control solenoid valve 8. Fuel pressure solenoid valve Index
connector 9. Vacuum hose connection
2. Fuel pressure solenoid valve 10. Brake booster vacuum hose
connector connection Group
3. Fuel vapour control hose 11. Detonation sensor connector TOC
connection 12. Bracket
4. Purge control solenoid valve 13. Inlet manifold stay
5. O-ring 14. Inlet manifold
6. Vacuum hose connection 15. Inlet manifold gasket
7. PCV hose connection

INSPECTION
M1151003100832
Check the following points; replace the part if a prob-
lem is found.
INLET MANIFOLD CHECK
1. Check for damage or cracking of any part.
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
15-14 INTAKE AND EXHAUST
EXHAUST MANIFOLD

EXHAUST MANIFOLD Main

Index
REMOVAL AND INSTALLATION <4A9>
M1151003301464

Pre-removal Operation Post-installation Operation Group

• Cowl Top Panel Removal (Refer to GROUP42, Loose • Front Exhaust Pipe Installation (Refer to GROUP15 TOC
Panel P.42-81). P.15-19).
• Front Exhaust Pipe Removal (Refer to GROUP 15 • Cowl Top Panel Installation (Refer to GROUP42, Loose
P.15-19). Panel P.42-81).

9.0 ± 1.0 N·m

3
4N

35 ± 2 N·m

30 ± 3 N·m

2
20 ± 1 N·m
5

30 ± 3 N·m

AC405244AB

Removal steps Removal steps (Continued)

1. Exhaust manifold cover 4. Exhaust manifold gasket
2. Exhaust manifold bracket B 5. Exhaust manifold bracket A
3. Exhaust manifold

INSPECTION <4A9>
M1151003400651
EXHAUST MANIFOLD CHECK
Check the following points; replace the part if a prob-
lem is found. 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
EXHAUST MANIFOLD AND TURBOCHARGER
15-15
EXHAUST MANIFOLD AND TURBOCHARGER Main
Index
REMOVAL AND INSTALLATION <4G1>
M1151008900350

Pre-removal Operation Post-installation Operation Group

• Engine air Intake Hose Removal (Refer to P.15-6).
• Engine Coolant Draining (Refer to GROUP 14, On-vehicle
Service − Engine Coolant Replacement P.14-6).
• Engine Oil Draining (Refer to GROUP 12, On-vehicle
Service − Engine Oil Replacement P.12-4).
• Front Catalytic Converter Removal (Refer to GROUP 17,
Catalytic Converter P.17-24).
• Front Catalytic Converter Installation (Refer to GROUP TOC
17, Catalytic converter P.17-24).
• Engine Oil Refilling (Refer to GROUP 12, On-vehicle
Service − Engine Oil Replacement P.12-4).
• Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
Service − Engine Coolant Replacement P.14-6).
• Engine air Intake Hose Installation (Refer to P.15-6).

17 ± 2 N·m
N 12
9.0 ± 1.0 N·m
5 6
10 ± 2 N·m

17 ± 2 N·m
10 ± 2 N·m 8
11
N 12 7

9.0 ± 1.0 N·m 9

10 ± 2 N·m

31 ± 2 N·m
10 ± 2 N·m 10 N

10 ± 2 N·m

1
50 ± 10 N·m
10 ± 2 N·m

2
3
11 ± 1 N·m

4 10 ± 2 N·m
AC405018AB

Removal steps Removal steps (Continued)

<<A>> >>D<< 1. Oxygen sensor 7. Turbocharger waste gate solenoid
2. Turbocharger cover valve, vacuum hose and vacuum
3. Pin pipe assembly
4. Turbocharger waste gate actuator 8. Turbocharger water return hose
5. Turbocharger waste gate solenoid connection
valve connector 9. Turbocharger water return pipe
6. Harness clamp connection 10. Gasket
<<B>> 11. Turbocharger oil feed tube
12. Gasket
15-16 INTAKE AND EXHAUST
EXHAUST MANIFOLD AND TURBOCHARGER

Main
Index

Group
TOC

29 N
59 ± 5 N·m

29 ± 3 N·m

27 N

49 ± 5 N·m

28
59 ± 5 N·m
22 N
20 27 N
31 ± 2 N·m
49 ± 5 N·m

23
21
24 N 59 ± 5 N·m
35 ± 6 N·m
18 N 15 N
24 ± 4 N·m
25
13
19 17
59 ± 5 N·m
16 N 14
10 ± 2 N·m
(Engine oil) N 26 35 ± 6 N·m

AC405028AB

Removal steps Removal steps (Continued)

13. Turbocharger oil return tube 20. Turbocharger water feed hose
>>C<< 14. Turbocharger oil return tube gasket connection
(oil pan side) >>A<< 21. Turbocharger assembly
>>B<< 15. Turbocharger oil return tube gasket 22. Gasket
(turbocharger assembly side) 23. Turbocharger water feed pipe
16. Bracket 24. Gasket
• Air outlet fitting (Refer to P.15-8). 25. Oil level gauge guide
17. Turbocharger exhaust outlet fitting 26. O-ring
18. Gasket 27. Nut
19. Bracket 28. Exhaust manifold
29. Exhaust manifold gasket
 INTAKE AND EXHAUST
EXHAUST MANIFOLD AND TURBOCHARGER
15-17
REMOVAL SERVICE POINTS >>B<< TURBOCHAGER OIL RETURN Main
<<A>> OXYGEN SENSOR REMOVAL TUBE GASKET (TURBOCHARGER Index
ASSEMBLY SIDE) INSTALLATION
Oxygen sensor <Turbocharger assembly side> Group
TOC

MB991953

Projection
AC301966AE

Remove the connection and clamp of oxygen sensor AC402401AD

connector, and then use special tool oxygen sensor Install the gasket as its protrusion is in the direction
wrench (MB991953) to remove the oxygen sensor. shown.

<<B>> TURBOCHARGER OIL FEED TUBE >>C<< TURBOCHAGER OIL RETURN

REMOVAL TUBE GASKET (OIL PAN SIDE)
CAUTION INSTALLATION
After removing the turbocharger oil feed tube, be <Oil pan side>
careful that any foreign materials does not get
into the oil passages of the turbocharger.

INSTALLATION SERVICE POINTS

>>A<< TURBOCHARGER ASSEMBLY
INSTALLATION Projection
(Brown printed)
1. Clean the turbocharger oil feed tube, water feed
pipe and water return pipe fitting, the inside of eye
AC402402 AC
bolts, and individual pipe for clogs.
With the print area on the gasket facing to the pipe,
CAUTION install the gasket so that the protrusion is in the direc-
Be careful that any foreign materials does not get tion shown in the figure.
into the turbocharger.
2. Clean or blow the air if carbon residues are stuck
to the oil passages of turbocharger assembly.
3. Add new engine oil through the turbocharger oil
feed tube of turbocharger assembly.
15-18 INTAKE AND EXHAUST
EXHAUST MANIFOLD AND TURBOCHARGER

>>D<< OXYGEN SENSOR INSTALLATION INSPECTION <4G1> Main

M1151003400662 Index
Check the following points; replace the part if a prob-
Oxygen sensor lem is found.
EXHAUST MANIFOLD CHECK Group
1. Check for damage or cracking of any part. TOC
MB991953 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
AC301966AE Limit: 0.20 mm
1. Tighten the oxygen sensor to the specified torque
by using special tool oxygen sensor wrench
(MB991953).
Tightening torque: 50 ± 10 N⋅m
2. Connect the oxygen sensor connector and install
the connector bracket.
 INTAKE AND EXHAUST
EXHAUST PIPE AND MAIN MUFFLER
15-19
EXHAUST PIPE AND MAIN MUFFLER Main
Index
REMOVAL AND INSTALLATION <4A9>
M1151008701315

Group
<M/T> 5 TOC

N 1
N 2

50 ± 10 N·m
50 ± 10 N·m 3
13 ± 2 N·m 31 ± 1 N·m
7
8 13 4
5

N 11
6
41 ± 10 N·m
N 10
59 ± 10 N·m
9 12 AC601364AB

<CVT> 5

N 1
N 2

50 ± 10 N·m 50 ± 10 N·m
3
13 ± 2 N·m 31 ± 1 N·m
7
8 13 4
5

N 11 6
N 10
41 ± 10 N·m
9 59 ± 10 N·m 12
AC601365AB

Exhaust main muffler removal Exhaust centre pipe removal

steps steps (Continued)
>>B<< 1. Exhaust pipe clamp 10. Exhaust pipe gasket
>>B<< 2. Exhaust pipe gasket 12. Exhaust muffler hanger
3. Exhaust main muffler 13. Exhaust pipe damper
4. Exhaust muffler hanger bracket Exhaust front pipe removal
stopper steps
5. Exhaust muffler hanger <<A>> >>A<< 7. Oxygen sensor
Exhaust centre pipe removal <<A>> >>A<< 8. Oxygen sensor
steps 9. Front exhaust pipe
>>B<< 1. Exhaust pipe clamp 10. Exhaust gasket
>>B<< 2. Exhaust pipe gasket 11. Seal ring
6. Centre exhaust pipe
15-20 INTAKE AND EXHAUST
EXHAUST PIPE AND MAIN MUFFLER

REMOVAL SERVICE POINT >>B<< EXHAUST PIPE GASKET / Main

<<A>> OXYGEN SENSOR REMOVAL EXHAUST PIPE CLAMP INSTALLATION Index

Oxygen sensor
Centre exhaust pipe Exhaust main muffler Group
TOC

MB991953

Exhaust pipe gasket

AC301966AB AC207712 AC

Remove the connection and clamp of oxygen sensor 1. Install the exhaust pipe gasket in the direction
connector, and then use special tool oxygen sensor shown in the illustration.
wrench (MB991953) to remove the oxygen sensor.
Exhaust main muffler
INSTALLATION SERVICE POINTS
Exhaust
>>A<< OXYGEN SENSOR INSTALLATION centre pipe

Oxygen sensor Concave

part

Concave Exhaust pipe

MB991953 part clamp AC207713 AD

2. Confirm that the exhaust main muffler and the

concave parts at the rear side of the centre
exhaust pipe are located as shown in the
AC301966AB
illustration. Install the exhaust pipe clamp so that
1. Tighten the oxygen sensor to the specified torque its mounting bolts are in the direction shown in the
by using special tool oxygen sensor wrench illustration.
(MB991953).
Tightening torque:50 ± 10 N⋅m
2. Connect the oxygen sensor connector and install
the connector bracket.
 INTAKE AND EXHAUST
EXHAUST PIPE AND MAIN MUFFLER
15-21
REMOVAL AND INSTALLATION <4G1> Main
M1151008701326 Index
5
Group
TOC
N2

N 3

50 ± 10 N·m 10
1 31 ± 1 N·m 4
7 N8
5
N9

6
59 ± 10 N·m
41 ± 10 N·m 10
AC601367AB

Exhaust main muffler removal Exhaust centre pipe removal

steps steps (Continued)
>>A<< 2. Exhaust pipe clamp 6. Centre exhaust pipe
>>A<< 3. Exhaust pipe gasket 8. Exhaust pipe gasket
4. Exhaust main muffler 10. Exhaust muffler hanger
5. Exhaust muffler hanger Exhaust front pipe removal
Exhaust centre pipe removal steps
steps 7. Front exhaust pipe
<<A>> >>B<< 1. Oxygen sensor 8. Exhaust pipe gasket
>>A<< 2. Exhaust pipe clamp 9. Seal ring
>>A<< 3. Exhaust pipe gasket
15-22 INTAKE AND EXHAUST
EXHAUST PIPE AND MAIN MUFFLER

REMOVAL SERVICE POINT Exhaust main muffler

Main
<<A>> OXYGEN SENSOR REMOVAL Index
Exhaust
centre pipe
Oxygen sensor
Group
TOC
Concave
part
MB991953
Concave Exhaust pipe
part clamp AC207713 AD

2. Confirm that the exhaust main muffler and the

AC301966AB
Remove the connection and clamp of oxygen sensor
connector, and then use special tool oxygen sensor
wrench (MB991953) to remove the oxygen sensor.
INSTALLATION SERVICE POINTS
>>A<< EXHAUST PIPE GAS-
KET/EXHAUST PIPE CLAMP INSTALLA-
TION
concave parts at the rear side of the centre
exhaust pipe are located as shown in the
illustration. Install the exhaust pipe clamp so that
its mounting bolts are in the direction shown in the
illustration.
>>B<< OXYGEN SENSOR INSTALLATION
Oxygen sensor

Centre exhaust pipe Exhaust main muffler

MB991953

AC301966AB

Exhaust pipe gasket 1. Tighten the oxygen sensor to the specified torque
AC207712 AC by using special tool oxygen sensor wrench
(MB991953).
1. Install the exhaust pipe gasket in the direction Tightening torque:50 ± 10 N⋅m
shown in the illustration.
2. Connect the oxygen sensor connector and install
the connector bracket.