TURBOCHARGER

<4M40>

The 4M40 engine uses the turbo charger (TF035HM-12T).

<4M41>

The 4M41 engine uses the turbo charger (TF035HL-14GK2).

INTERCOOLER <4M4>

The intercooler assembly is located underneath at the bottom of the radiator to maintain forward and
downward visibility in the same way as the conventional PAJERO.

SPECIFICATIONS

Item Specification
Type Air cooling type
Core size mm Width × Height × Thickness 350 × 187 × 64
Performance kJ/h 28,764

CONSTRUCTION DIAGRAM

<4M40>
<4M41>
EXHAUST MANIFOLD

<6G7>

Stainless steel plate is used to assure light saving.

<4M40>

The exhaust manifold made of cast iron is used due to the heat capacity and the durability.

<4M41>

The exhaust manifold made of cast iron is used due to the heat capacity and the durability.
INLET MANIFOLD

<6G72>

The inlet manifold consists of the air intake fitting, the upper inlet manifold and the lower inlet manifold.

<6G75>

The air intake port of the each cylinder on the inlet manifold has been divided into the primary port. and
the secondary port.
The control valve has been installed to the secondary port, and this control valve is opened or closed
through the vacuum actuator depending on the engine speed.
That is an air inlet control system which has been adopted. This system has prevented the typical 4-
valve engine low performance at the low speed and improved the fuel economy within the range of the
low to the middle speed.
That is, this system uses the primary port only at the low speed and then makes the inlet airflow speed
high, so increases the inertia supercharging effect.

<4M40>

Aluminium alloy inlet manifold is used.

<4M41>

This 4M41 is designed to be a cross flow to improve

an intake efficiency.
AIR DUCT AND AIR CLEANER

The air duct and air cleaner basically have the same system as those of the conventional
PAJERO. The intake port of the air duct is located at the top of the radiator to provide a layout
which effectively draws in the cooling air. This boosts engine output performance and reduces the
amount of intake air noise inside the passenger compartment.
For the air intake hose, the resonator has been added to reduce intake noise <6G7>.
For the air cleaner intake duct, the resonator and branch pipe has been added to reduce intake
noise <6G75>.
A pre-cleaner has been provided to reduce the tendency of the air cleaner element to become
blocked quickly.

CONSTRUCTION DIAGRAM

<6G72>
<6G75>
<4M40>
<4M41>
EXHAUST PIPE AND MUFFLER <6G72>

5-piece type of short wheelbase exhaust pipe which consists of the front exhaust pipe (L.H.), front
exhaust pipe (R.H.), catalytic converter, centre exhaust pipe and exhaust main muffler has been
adopted.
5-piece type of long wheelbase exhaust pipe which consists of the front exhaust pipe (L.H.), front
exhaust pipe (R.H.), pre-muffler assembly or catalytic converter, exhaust main muffler and exhaust tail
pipe has been adopted.
The exhaust pipe and muffler is basically the same as the conventional PAJERO.

CONSTRUCTION DIAGRAM

<Short wheelbase>
<Long wheelbase (vehicles without catalytic converter)>
<Long wheelbase (vehicles with catalytic converter)>
EXHAUST PIPE AND MUFFLER <6G75>

5-piece type of short wheelbase exhaust pipe which consists of the front exhaust pipe, front catalytic
converter, rear catalytic converter, centre exhaust pipe and exhaust main muffler has been adopted.
5-piece type of long wheelbase exhaust pipe which consists of the front exhaust pipe, front catalytic
converter, rear catalytic converter, exhaust main muffler and exhaust tail pipe has been adopted.
The exhaust pipe and muffler is basically the same as the conventional PAJERO.

CONSTRUCTION DIAGRAM

<Short wheelbase>
<Long wheelbase>
EXHAUST PIPE AND MUFFLER <4M41>

5-piece type of short wheelbase exhaust pipe which consists of the front catalytic converter, front
exhaust pipe, front exhaust pipe, centre exhaust pipe and exhaust main muffler has been adopted.
5-piece type of long wheelbase exhaust pipe which consists of the front catalytic converter, front
exhaust pipe, front exhaust pipe, exhaust main muffler and exhaust tail pipe has been adopted.
This exhaust pipe and muffler have been established by adding the front catalytic converter to the ones
for the conventional PAJERO.

CONSTRUCTION DIAGRAM

<Short wheelbase>
<Long wheelbase>
EXHAUST PIPE AND MUFFLER <4M40>

4-piece type of short wheelbase exhaust pipe which consists of the front exhaust pipe, pre-muffler
assembly, centre exhaust pipe and exhaust main muffler has been adopted.
4-piece type of long wheelbase exhaust pipe which consists of the front exhaust pipe, pre-muffler
assembly, exhaust main muffler and exhaust tail pipe has been adopted.
The exhaust pipe and muffler is basically the same as the conventional PAJERO.

CONSTRUCTION DIAGRAM

<Short wheelbase>
<Long wheelbase>
SWIRL CONTROL VALVE (SCV) SOLENOID
CHECK <4M41>
1.Disconnect the vacuum hoses from the SCV solenoid.
When disconnecting the vacuum hose,
note always make sure that it can be
reconnected at its original position.
2.Disconnect the harness connector.
3.Connect a hand vacuum pump to nipple (B) of the
SCV solenoid.
4.As described in the chart below, check airtightness
by applying a vacuum with voltage applied directly from
the battery to the SCV solenoid, and without applying
voltage.
Battery Nipple Normal
positive (A) condition
voltage condition
Applied Open Vacuum
leaks
Closed Vacuum
maintained
Not Open Vacuum
applied leaks
5.Measure the resistance between the terminals of the
SCV solenoid.
Standard value: 29 - 35 Ω (at 20°C)
6.Replace the solenoid if airtightness or resistance is
out of specification.
SWIRL CONTROL VALVE (SCV) SYSTEM
CHECK <4M41>
1.Warm up the engine.
2.Disconnect the vacuum hose from the SCV actuator,
and then connect a vacuum gauge via the Tee-fitting.
3.Start the engine and verify that a vacuum is applied
to the vacuum gauge.
4.As described in the chart below, vary the engine
speed to inspect the vacuum conditions. During this
inspection, verify that the rod of the SCV actuator is
operating.
Engine Normal Control
speed condition valve
2,800 Vacuum Closed
r/min or maintained
less
3,200 Vacuum Open
r/min or leaks
more
VACUUM TANK CHECK <6G75>
1.Disconnect the vacuum hoses from the vacuum tank.
When disconnecting the vacuum
note hose, always make sure that it can
be reconnected at its original
position.
2.Connect a hand vacuum pump to nipple "A" of the
vacuum tank, apply a vacuum of 67 kPa, and verify that
the vacuum is maintained.
3.Disconnect the hand vacuum pump from nipple "A"
and connect it to nipple "B".
4.Block nipple "A" with your finger and apply a vacuum
of 67 kPa to nipple "B". Release your finger from
nipple "A" and verify that the vacuum leaks
immediately.
5.Replace the vacuum tank if it is faulty.
VARIABLE INDUCTION CONTROL (VIC)
SOLENOID VALVE CHECK <6G75>
1.Disconnect the vacuum hoses from the VIC solenoid
valve.
When disconnecting the vacuum hose,
note always make sure that it can be
reconnected at its original position.
2.Disconnect the harness connector.
3.Connect a hand vacuum pump to nipple (B) of the
variable induction control solenoid valve.
4.As described in the chart below, check airtightness
by applying a vacuum with voltage applied directly from
the battery to the VIC solenoid, and without applying
voltage.
Battery Nipple Normal
positive (A) condition
voltage condition
Applied Open Vacuum
leaks
Closed Vacuum
maintained
Not Open Vacuum
applied leaks
5.Measure the resistance between the terminals of the
VIC solenoid.
Standard value: 29 - 35 Ω (at 20°C)
6.Replace the solenoid if airtightness or resistance is
out of specification.
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 feeler gauge, check for
distortion of the cylinder head installation surface.

Standard value: 0.15 mm or less

Limit: 0.20 mm

TURBOCHARGER ASSEMBLY
CHECK

1.Visually check the turbine wheel and the compressor

wheel for cracking or other damage.
2.Check whether the turbine wheel and the compressor
wheel can be easily turned by hand.
3.Check for oil leakage from the turbocharger assembly.
4.Check whether or not the turbocharger waste gate
regulating valve remains open. If any problem is found,
replace the part after disassembly.

OIL PIPE AND OIL RETURN PIPE

CHECK

Check the oil pipe and oil return pipe for clogging, bending
or other damage. If there is clogging, clean it.
REMOVAL AND INSTALLATION
Pre-removal Operation
Engine Cover Removal (Refer to GROUP
11G - Engine Assembly )
Under Skid Plate and Engine Room Under
Cover (Front) Removal (Refer to GROUP 51
- Under Cover ).
Engine Coolant Draining (Refer to GROUP
14 - On-vehicle Service, Engine Coolant
Replacement ).
Engine Oil Draining <4M4> (Refer to
GROUP 12 - On-vehicle Service, Engine Oil
Replacement ).
Air Cleaner Assembly Removal <4M4>
(Refer to ).
EGR Pipe B Assembly, EGR Cooler
Assembly Removal (Refer to GROUP 17 -
Emission Control, EGR Valve and EGR
Cooler ).
Front Catalytic Converter Removal <4M41>
(Refer to ).
Turbocharger Water Inlet Pipe,
Turbocharger Water Outlet Pipe Removal
<4M41> (Refer to GROUP 14 - Water Hose
and Water Pipe ).
Post-installation Operation
Turbocharger Water Inlet Pipe, Turbocharger
Water Outlet Pipe Installation <4M41> (Refer
to GROUP 14 - Water Hose and Water Pipe
).
Front Catalytic Converter Installation
<4M41> (Refer to ).
EGR Pipe B Assembly, EGR Cooler
Assembly Installation (Refer to GROUP 17 -
Emission Control, EGR Valve and EGR
Cooler ).
Air Cleaner Assembly Installation <4M4>
(Refer to ).
Engine Oil Refilling <4M4> (Refer to GROUP
12 - On-vehicle Service, Engine Oil
Replacement ).
Engine Coolant Refilling (Refer to GROUP
14 - On-vehicle Service, Engine Coolant
Replacement ).
Under Skid Plate and Engine Room Under
Cover (Front) Installation (Refer to GROUP
51 - Under Cover ).
Engine Cover Installation (Refer to GROUP
11G - Engine Assembly ).
 Removal
steps
1. Turbocharger
heat
protector
2. Vacuum
hose
3. Snap ring
4. Waste gate
actuator
5. Oil return
hose
6. Oil return
pipe
>>C<< 7. Gasket
8. Oil pipe
assembly
9. Gasket
>>B<< 10. Turbocharger
assembly
11. Gasket
12. Exhaust
manifold heat
protector
>>A<< 13. Exhaust
manifold
14. Exhaust
manifold
gasket

INSTALLATION SERVICE POINTS

>>A<< EXHAUST MANIFOLD

INSTALLATION

Before using the tool to remove the exhaust manifold, move

the heater hose clamp to a position where the tool would
not interfere with it.
>>B<< 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.
caution Be careful not to allow foreign material
to enter the turbocharger.
If deposits of carbon are accumulated on the turbocharger
oil passage, remove them and clean using the compressed
air.
3.Add clean engine oil through the oil feed pipe port on the
turbocharger.

>>C<< GASKET INSTALLATION

The tab on the oil return pipe gasket should be position

as shown.
REMOVAL AND INSTALLATION <6G75-
STEP4>

<SHORT WHEELBASE>

Exhaust
main
muffler
and rear
floor heat
protector
removal
steps
1. Exhaust
main
muffler
3. Exhaust
pipe
gasket
4. Exhaust
muffler
hanger
5. Hanger
bracket
6. Hanger
bracket
7. Rear floor
heat
protector
Centre
exhaust
pipe
removal
steps
2. Centre
exhaust
pipe
3. Exhaust
pipe
gasket
18. Exhaust
pipe
gasket
 19. Exhaust
muffler
hanger
20. Hanger
bracket
Rear
catalytic
converter
removal
steps
16. Rear
catalytic
converter
17. Seal ring
18. Exhaust
pipe
gasket
Front
exhaust
pipe,
front
catalytic
converter
and dash
panel
heat
protector
removal
steps
· Under
skid plate
and
engine
room
under
cover
(Refer to
GROUP
51 - Under
Cover )
<<A>> >>A<< 8. Right
bank
oxygen
sensor
(front)
9. Front
exhaust
pipe
10. Exhaust
pipe
gasket
<<A>> >>A<< 11. Left bank
oxygen
sensor
(front)
<<A>> >>A<< 12. Right
bank
oxygen
sensor
(rear)
<<A>> >>A<< 13. Left bank
oxygen
sensor
(rear)
14. Front
catalytic
converter
15. Exhaust
pipe
gasket
17. Seal ring
21. Exhaust
support
bracket
22. Dash
panel heat
protector
Front
floor heat
protector
removal
steps
· Under
skid plate
and
engine
room
under
cover
(Refer to
GROUP
51 - Under
Cover )
<<A>> >>A<< 8. Right
bank
oxygen
sensor
(front)
9. Front
exhaust
pipe
 10. Exhaust
pipe
gasket
<<A>> >>A<< 11. Left bank
oxygen
sensor
(front)
<<A>> >>A<< 12. Right
bank
oxygen
sensor
(rear)
<<A>> >>A<< 13. Left bank
oxygen
sensor
(rear)
14. Front
catalytic
converter
15. Exhaust
pipe
gasket
16. Rear
catalytic
converter
17. Seal ring
18. Exhaust
pipe
gasket
22. Dash
panel heat
protector
23. Front floor
heat
protector

<LONG WHEELBASE>

Exhaust
tail pipe
and rear
floor heat
protector
removal
steps
1. Exhaust
tail pipe
3. Exhaust
pipe
gasket
4. Exhaust
muffler
hanger
5. Hanger
bracket
6. Hanger
bracket
7. Rear floor
heat
protector
Exhaust
main
muffler
removal
steps
2. Exhaust
main
muffler
3. Exhaust
pipe
gasket
18. Exhaust
pipe
gasket
19. Exhaust
muffler
hanger
20. Hanger
bracket
Rear
catalytic
converter
removal
steps
16. Rear
catalytic
converter
17. Seal ring
18. Exhaust
pipe
gasket
 Front
exhaust
pipe,
front
catalytic
converter
and dash
panel
heat
protector
removal
steps
· Under
skid plate
and
engine
room
under
cover
(Refer to
GROUP
51 - Under
Cover )
<<A>> >>A<< 8. Right
bank
oxygen
sensor
(front)
9. Front
exhaust
pipe
10. Exhaust
pipe
gasket
<<A>> >>A<< 11. Left bank
oxygen
sensor
(front)
<<A>> >>A<< 12. Right
bank
oxygen
sensor
(rear)
<<A>> >>A<< 13. Left bank
oxygen
sensor
(rear)
14. Front
catalytic
converter
 15. Exhaust
pipe
gasket
17. Seal ring
21. Exhaust
support
bracket
22. Dash
panel heat
protector
Front
floor heat
protector
removal
steps
· Under
skid plate
and
engine
room
under
cover
(Refer to
GROUP
51 - Under
Cover )
<<A>> >>A<< 8. Right
bank
oxygen
sensor
(front)
9. Front
exhaust
pipe
10. Exhaust
pipe
gasket
<<A>> >>A<< 11. Left bank
oxygen
sensor
(front)
<<A>> >>A<< 12. Right
bank
oxygen
sensor
(rear)
<<A>> >>A<< 13. Left bank
oxygen
sensor
(rear)
 14. Front
catalytic
converter
15. Exhaust
pipe
gasket
16. Rear
catalytic
converter
17. Seal ring
18. Exhaust
pipe
gasket
22. Dash
panel heat
protector
23. Front floor
heat
protector

REMOVAL SERVICE POINT

<<A>> OXYGEN SENSOR

REMOVAL

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 POINT

>>A<< OXYGEN SENSOR

INSTALLATION

1.Tighten the oxygen sensor to the specified torque by

using special tool oxygen sensor wrench (MB991953).
Tightening torque: 44 ± 5 N·m
2.Connect the oxygen sensor connector and install the
connector bracket.
REMOVAL AND INSTALLATION <6G75-
STEP2>

<SHORT WHEELBASE>

Exhaust
main
muffler
and rear
floor heat
protector
removal
steps
1. Exhaust
main
muffler
3. Exhaust
pipe
gasket
4. Exhaust
muffler
hanger
5. Hanger
bracket
6. Hanger
bracket
7. Rear floor
heat
protector
Centre
exhaust
pipe
removal
steps
2. Centre
exhaust
pipe
3. Exhaust
pipe
gasket
15. Exhaust
pipe
gasket
 16. Exhaust
muffler
hanger
17. Hanger
bracket
Rear
catalytic
converter
removal
steps
13. Catalytic
converter
14. Seal ring
15. Exhaust
pipe
gasket
Front
exhaust
pipe,
front
catalytic
converter
and dash
panel
heat
protector
removal
steps
· Under
skid plate
and
engine
room
under
cover
(Refer to
GROUP
51 - Under
Cover )
8. Front
exhaust
pipe (RH)
9. Exhaust
pipe
gasket
<<A>> >>A<< 10. Left bank
oxygen
sensor
(front)
 11. Front
exhaust
pipe (LH)
12. Exhaust
pipe
gasket
14. Seal ring
Front
floor heat
protector
removal
steps
· Under
skid plate
and
engine
room
under
cover
(Refer to
GROUP
51 - Under
Cover )
9. Front
exhaust
pipe
10. Exhaust
pipe
gasket
<<A>> >>A<< 11. Left bank
oxygen
sensor
(front)
11. Front
exhaust
pipe (LH)
12. Exhaust
pipe
gasket
13. Catalytic
converter
14. Seal ring
15. Exhaust
pipe
gasket
18. Front floor
heat
protector

<LONG WHEELBASE>
 Exhaust
main
muffler
and rear
floor heat
protector
removal
steps
1. Exhaust
main
muffler
3. Exhaust
pipe
gasket
4. Exhaust
muffler
hanger
5. Hanger
bracket
6. Hanger
bracket
7. Rear floor
heat
protector
Centre
exhaust
pipe
removal
steps
2. Centre
exhaust
pipe
3. Exhaust
pipe
gasket
15. Exhaust
pipe
gasket
16. Exhaust
muffler
hanger
17. Hanger
bracket
Rear
catalytic
converter
removal
steps
 13. Catalytic
converter
14. Seal ring
15. Exhaust
pipe
gasket
Front
exhaust
pipe,
front
catalytic
converter
and dash
panel
heat
protector
removal
steps
· Under
skid plate
and
engine
room
under
cover
(Refer to
GROUP
51 - Under
Cover )
8. Front
exhaust
pipe (RH)
9. Exhaust
pipe
gasket
<<A>> >>A<< 10. Left bank
oxygen
sensor
(front)
11. Front
exhaust
pipe (LH)
12. Exhaust
pipe
gasket
14. Seal ring
Front
floor heat
protector
removal
steps
 · Under
skid plate
and
engine
room
under
cover
(Refer to
GROUP
51 - Under
Cover )
9. Front
exhaust
pipe
10. Exhaust
pipe
gasket
<<A>> >>A<< 11. Left bank
oxygen
sensor
(front)
11. Front
exhaust
pipe (LH)
12. Exhaust
pipe
gasket
13. Catalytic
converter
14. Seal ring
15. Exhaust
pipe
gasket
18. Front floor
heat
protector

REMOVAL SERVICE POINT

<<A>> OXYGEN SENSOR

REMOVAL

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 POINT

>>A<< OXYGEN SENSOR

INSTALLATION

1.Tighten the oxygen sensor to the specified torque by

using special tool oxygen sensor wrench (MB991953).
Tightening torque: 44 ± 5 N·m
2.Connect the oxygen sensor connector and install the
connector bracket.
REMOVAL AND INSTALLATION <6G72>

<SHORT WHEELBASE>

Exhaust
main
muffler
and rear
floor heat
protector
removal
steps
1. Exhaust
main
muffler
3. Exhaust
pipe
gasket
4. Exhaust
muffler
hanger
5. Hanger
bracket
6. Hanger
bracket
7. Rear floor
heat
protector
Centre
exhaust
pipe
removal
steps
2. Centre
exhaust
pipe
3. Exhaust
pipe
gasket
15. Exhaust
pipe
gasket
16. Exhaust
muffler
hanger
 17. Hanger
bracket
Catalytic
converter
removal
steps
13. Rear
catalytic
converter
14. Seal ring
15. Exhaust
pipe
gasket
Front
exhaust
pipe
removal
steps
· Under
skid plate
and
engine
room
under
cover
(Refer to
GROUP
51 - Under
Cover )
8. Front
exhaust
pipe
(R.H.)
9. Exhaust
pipe
gasket
<<A>> >>A<< 10. Oxygen
sensor
11. Front
exhaust
pipe (L.H.)
12. Exhaust
pipe
gasket
14. Seal ring
Front
floor heat
protector
removal
steps
 · Under
skid plate
and
engine
room
under
cover
(Refer to
GROUP
51 - Under
Cover )
8. Front
exhaust
pipe
(R.H.)
9. Exhaust
pipe
gasket
<<A>> >>A<< 10. Oxygen
sensor
11. Front
exhaust
pipe (L.H.)
12. Exhaust
pipe
gasket
13. Catalytic
converter
14. Seal ring
15. Exhaust
pipe
gasket
18. Front floor
heat
protector

<LONG WHEELBASE>

Exhaust
tail pipe
and rear
floor heat
protector
removal
steps
1. Exhaust
tail pipe
3. Exhaust
pipe
gasket
4. Exhaust
muffler
hanger
5. Hanger
bracket
6. Hanger
bracket
7. Rear floor
heat
protector
Exhaust
main
muffler
removal
steps
2. Exhaust
main
muffler
3. Exhaust
pipe
gasket
16. Exhaust
pipe
gasket
17. Exhaust
muffler
hanger
18. Hanger
bracket
Catalytic
converter
removal
steps
13. Catalytic
converter
15. Seal ring
16. Exhaust
pipe
gasket
Pre-
muffler
removal
steps
14. Pre-
muffler
15. Seal ring
 16. Exhaust
pipe
gasket
Front
exhaust
pipe
removal
steps
· Under
skid plate
and
engine
room
under
cover
(Refer to
GROUP
51 - Under
Cover )
8. Front
exhaust
pipe
(R.H.)
9. Exhaust
pipe
gasket
<<A>> >>A<< 10. Oxygen
sensor
11. Front
exhaust
pipe (L.H.)
12. Exhaust
pipe
gasket
15. Seal ring
Front
floor heat
protector
removal
steps
· Under
skid plate
and
engine
room
under
cover
(Refer to
GROUP
51 - Under
Cover )
 8. Front
exhaust
pipe
(R.H.)
9. Exhaust
pipe
gasket
<<A>> >>A<< 10. Oxygen
sensor
11. Front
exhaust
pipe (L.H.)
12. Exhaust
pipe
gasket
13. Catalytic
converter
15. Seal ring
16. Exhaust
pipe
gasket
19. Front floor
heat
protector

REMOVAL SERVICE POINT

<<A>> OXYGEN SENSOR

REMOVAL

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 POINT

>>A<< OXYGEN SENSOR

INSTALLATION
1.Tighten the oxygen sensor to the specified torque by
using special tool oxygen sensor wrench (MB991953).
Tightening torque: 44 ± 5 N·m
2.Connect the oxygen sensor connector and install the
connector bracket.
REMOVAL AND INSTALLATION <4M40>

<SHORT WHEELBASE>

Exhaust main
muffler and rear
floor heat
protector removal
steps
1. Exhaust main
muffler
3. Exhaust pipe
gasket
4. Exhaust muffler
hanger
5. Hanger bracket
6. Hanger bracket
7. Rear floor heat
protector
Centre exhaust
pipe removal
steps
2. Centre exhaust
pipe
3. Exhaust pipe
gasket
13. Exhaust pipe
gasket
14. Exhaust muffler
hanger
15. Hanger bracket
Pre-muffler
assembly removal
steps
10. Pre-muffler
assembly
11. Seal ring
13. Exhaust pipe
gasket
Front exhaust
pipe and dash
panel heat
protector removal
steps
 · Under skid plate
and engine room
under cover (Refer
to GROUP 51 -
Under Cover )
8. Front exhaust pipe
9. Exhaust pipe
gasket
11. Seal ring
12. Dash panel heat
protector

<LONG WHEELBASE>

Exhaust tail and

rear floor heat
protector removal
steps
1. Exhaust tail pipe
3. Exhaust pipe
gasket
4. Exhaust muffler
hanger
5. Hanger bracket
6. Hanger bracket
7. Rear floor heat
protector
Exhaust main
muffler removal
steps
2. Exhaust main
muffler
3. Exhaust pipe
gasket
14. Exhaust pipe
gasket
15. Exhaust muffler
hanger
16. Hanger bracket
Pre-muffler
assembly removal
steps
10. Pre-muffler
assembly
11. Seal ring
14. Exhaust pipe
gasket
Front exhaust
pipe and dash
panel heat
protector removal
steps
· Under skid plate
and engine room
under cover (Refer
to GROUP 51 -
Under Cover )
8. Front exhaust pipe
9. Exhaust pipe
gasket
11. Seal ring
12. Exhaust support
bracket
13. Dash panel heat
protector
REMOVAL AND INSTALLATION

<SHORT WHEELBASE>

Exhaust main
muffler and rear
floor heat
protector removal
steps
1. Exhaust main
muffler
3. Exhaust pipe
gasket
4. Exhaust muffler
hanger
5. Hanger bracket
6. Hanger bracket
7. Rear floor heat
protector
Centre exhaust
pipe removal
steps
2. Centre exhaust
pipe
3. Exhaust pipe
gasket
12. Exhaust pipe
gasket
13. Exhaust muffler
hanger
14. Hanger bracket
Front exhaust
pipe and front
floor heat
protector removal
steps
10. Front exhaust pipe
11. Seal ring
12. Exhaust pipe
gasket
15. Front floor heat
protector
 Front exhaust
pipe, front
catalytic
converter and
dash panel heat
protector removal
steps
· Under skid plate
and engine room
under cover (Refer
to GROUP 51 -
Under Cover )
8. Front exhaust pipe
9. Exhaust pipe
gasket
11. Seal ring
16. Exhaust support
bracket
· Air cleaner
assembly <4M4>
(Refer to )
17. Front catalytic
converter cover
18. Front catalytic
converter
19. Exhaust pipe
gasket
20. Dash panel heat
protector

<LONG WHEELBASE>

Exhaust tail and

rear floor heat
protector removal
steps
1. Exhaust tail pipe
3. Exhaust pipe
gasket
4. Exhaust muffler
hanger
5. Hanger bracket
6. Hanger bracket
7. Rear floor heat
protector
 Exhaust main
muffler removal
steps
2. Exhaust main
muffler
3. Exhaust pipe
gasket
12. Exhaust pipe
gasket
13. Exhaust muffler
hanger
14. Hanger bracket
Front exhaust
pipe and front
floor heat
protector removal
steps
10. Front exhaust pipe
11. Seal ring
12. Exhaust pipe
gasket
15. Front floor heat
protector
Front exhaust
pipe, front
catalytic
converter and
dash panel heat
protector removal
steps
· Under skid plate
and engine room
under cover (Refer
to GROUP 51 -
Under Cover )
8. Front exhaust pipe
9. Exhaust pipe
gasket
11. Seal ring
16. Exhaust support
bracket
· Air cleaner
assembly <4M4>
(Refer to )
17. Front catalytic
converter cover
18. Front catalytic
converter
19. Exhaust pipe
gasket
20. Dash panel heat
protector
INSPECTION

Check the following points; replace the part if a problem is

found.

TURBOCHARGER ASSEMBLY
CHECK

1.Visually check the turbine wheel and the compressor

wheel for cracking or other damage.
2.Check whether the turbine wheel and the compressor
wheel can be easily turned by hand.
3.Check for oil leakage from the turbocharger assembly.
4.Check whether or not the turbocharger waste gate
regulating valve remains open. If any problem is found,
replace the part after disassembly.

OIL PIPE AND OIL RETURN PIPE

CHECK

Check the oil pipe and oil return pipe for clogging, bending
or other damage. If there is clogging, clean it.
REMOVAL AND INSTALLATION

Pre-removal Operation Post-installation Operation

Under Skid Plate and Engine Room Under
Cover Front Removal (Refer to GROUP 51 -
Under Cover ).
Engine Oil Draining <4M4> (Refer to
GROUP 12 - On-vehicle Service, Engine Oil
Replacement ).
Air Cleaner Assembly Removal <4M4>
(Refer to ).
Intercooler Air Hose A1 and Intercooler Air
Hose B Removal (Refer to ).
Front Exhaust Pipe Removal <4M40>
(Refer to ).
Front Exhaust Pipe Installation <4M40>
(Refer to ).
Intercooler Air Hose A1 and Intercooler Air
Hose B Installation (Refer to ).
Air Cleaner Assembly Installation <4M4>
(Refer to ).
Engine Oil Refilling <4M4> (Refer to GROUP
12 - On-vehicle Service, Engine Oil
Replacement ).
Under Skid Plate and Engine Room Under
Cover Front Installation (Refer to GROUP 51
- Under Cover ).

Removal
steps
1. Air intake
hose
2. Air intake
pipe
3. Turbocharger
cover B
4. Turbocharger
oil pipe
5. Gasket
6. Oil return
hose
7. Oil return
pipe
8. Gasket
9. Boost hose
connection
>>A<< 10. Turbocharger
assembly
11. Turbocharger
inlet gasket
12. Vacuum
hose
13. Waste gate
actuator
14. Turbocharger
cover A
 15. Exhaust
fitting cover
16. Exhaust
fitting
assembly
17. Exhaust
fitting gasket
18. Exhaust
manifold heat
protector
19. Exhaust
manifold heat
protector A
20. Exhaust
manifold
assembly
21. Exhaust
manifold
gasket
22. Cover B
23. Gasket
24. Earth cable
connection
25. Vacuum pipe
connection
26. Inlet manifold
assembly
27. Inlet manifold
gasket
28. Stay
29. Cover A
30. Gasket
31. Relief valve

INSTALLATION SERVICE POINT

>>A<< TURBOCHARGER
ASSEMBLY INSTALLATION

1.Check the internal surface, the eye bolt and the mating
surface of the oil pipe for clogging, and clean if necessary.
2.
caution Be careful not to allow foreign material
to enter the turbocharger.
If deposits of carbon are accumulated on the turbocharger
oil passage, remove them and clean using the compressed
air.
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 feeler gauge, check for
distortion of the cylinder head installation surface.

Standard value: 0.5 mm or less

Limit: 0.90 mm
REMOVAL AND INSTALLATION

<6G72>

Pre-removal and Post-installation Operation

Under Skid Plate and Engine Room Under Cover (Front) Removal and Installation (Refer to
GROUP 51 - Under Cover ).

Exhaust
manifold
(L.H.)
removal
steps
· Battery and
Battery Tray
Removal
(Refer to
GROUP 54A -
Battery ).
· A/T fluid level
gauge and
guide
assembly
(Refer to
GROUP 11A -
Oil pan and
Oil Strainer ).
· Engine oil
level gauge
and guide
assembly
(Refer to
GROUP 11A -
Oil pan and
Oil Strainer ).
· Front exhaust
pipe <6G72>
(Refer to ).
1. EGR pipe
assembly
>>B<< 2. EGR pipe
gasket
3. Exhaust
manifold
cover (L.H.)
 4. Exhaust
manifold
(L.H.)
>>A<< 5. Exhaust
manifold
gasket
Exhaust
manifold
(R.H.)
removal
steps
· Air cleaner
assembly
<6G7> (Refer
to ).
· Steering
column
support
bracket
connecting
bolts (Refer to
GROUP 37--
Steering Shaft
) <R.H. drive
vehicles>.
· Front exhaust
pipe (R.H.)
<6G72>
(Refer to )
6. Exhaust
manifold
cover (R.H.)
7. Exhaust
manifold
(R.H.)
>>A<< 8. Exhaust
manifold
gasket

<6G75>

Pre-removal Operation Post-installation Operation

Engine Cover Removal (Refer to GROUP
11C - Engine Assembly ).
Under Skid Plate and Engine Room Under
Cover (Front) Removal (Refer to GROUP
51 - Under Cover ).
Under Skid Plate and Engine Room Under
Cover (Front) Installation (Refer to GROUP
51 - Under Cover ).
Engine Cover Installation (Refer to GROUP
11C - Engine Assembly ).
 Exhaust
manifold
(L.H.)
removal
steps
· Battery and
Battery Tray
Removal
(Refer to
GROUP 54A -
Battery ).
· Engine oil
level gauge
and guide
Assembly
(Refer to
GROUP 11C -
Oil pan and
Oil Strainer ).
· A/T fluid level
gauge and
guide (Refer
to GROUP
11C - Oil pan
and Oil
Strainer ).
· Front catalytic
converter
<6G75-STEP
2> (Refer to ),
<6G75-STEP
4> (Refer to ).
1. Exhaust
manifold
cover (L.H.)
2. Exhaust
manifold
(L.H.)
>>A<< 3. Exhaust
manifold
gasket
Exhaust
manifold
(R.H.)
removal
steps
· Air cleaner
assembly
<6G7> (Refer
to ).
 · Steering
column
support
bracket
connecting
bolts (Refer to
GROUP 37 -
Steering Shaft
) <R.H. drive
vehicles>.
· Front exhaust
pipe <6G75-
STEP 2>
(Refer to ),
<6G75-STEP
4> (Refer to ).
4. Exhaust
manifold EGR
pipe
>>B<< 5. Exhaust
manifold EGR
pipe gasket
6. Exhaust
manifold
cover (R.H.)
7. Exhaust
manifold
(R.H.)
>>A<< 8. Exhaust
manifold
gasket

INSTALLATION SERVICE POINTS

>>A<< EXHAUST MANIFOLD

GASKET INSTALLATION

Install the exhaust manifold gasket as its protrusion is

in the direction shown.

>>B<< EXHAUST MANIFOLD EGR

PIPE GASKET INSTALLATION

Install the exhaust manifold EGR pipe gasket as its

protrusion is in the direction shown.
INSPECTION

Check the following points; replace the part if a problem is

found.

INLET MANIFOLD CHECK

1.Check for damage or cracking of any part.

2.Clogging of the negative pressure (vacuum) outlet port.
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
REMOVAL AND INSTALLATION <4M41>

Pre-removal Operation Post-installation Operation

Engine Cover Removal (Refer to GROUP
11G - Engine Assembly ).
Throttle Body Removal (Refer to GROUP
13D - Throttle Body ).
EGR Valve and EGR Pipe Removal (Refer
to GROUP 17 - Emission Control, EGR
Valve and EGR Cooler ).
EGR Valve and EGR Pipe Installation (Refer
to GROUP 17 - Emission Control, EGR
Valve and EGR Cooler ).
Throttle Body Installation (Refer to GROUP
13D - Throttle Body ).
Engine Cover Installation (Refer to GROUP
11G - Engine Assembly ).

Removal steps
1. Control wiring
harness connection
2. Vacuum hose
3. Vacuum pipe
assembly
4. Fuel return B pipe
assembly
5. No.2 intake air
temperature sensor
6. Gasket
7. Harness bracket
8. Engine cover B
bracket
9. Air inlet pipe
10. Gasket
11. Harness bracket
12. Harness bracket
· Fuel supply pump
pipe assembly, fuel
injection pipe
assembly, common
rail assembly, fuel
pipe bracket (Refer
to GROUP 13D -
Fuel Injector and
Common Rail ).
13. Spring
14. Retainer
15. Inlet manifold
assembly
16. Inlet manifold
gasket
REMOVAL AND INSTALLATION <6G75>

Pre-removal Operation Post-installation Operation

Fuel Line Pressure Reduction [Refer to GROUP 13B -
On-vehicle Service, Fuel Pump Connector
Disconnection (How to Reduce Pressurized Fuel
Lines) ].
Engine Coolant Draining (Refer to GROUP 14 - On-
vehicle Service, Engine Coolant Replacement ).
Engine Cover Removal (Refer to GROUP 11C -
Engine Assembly ).
Air Cleaner Assembly Removal <6G7> (Refer to ).
Throttle Body Assembly Removal (Refer to GROUP
13B - Throttle Body Assembly ).
EGR Valve Removal <6G75> (Refer to GROUP 17 -
Emission Control, EGR Valve ).
EGR Valve Installation <6G75>
(Refer to GROUP 17 - Emission
Control, EGR Valve ).
Throttle Body Assembly
Installation (Refer to GROUP 13B
- Throttle Body Assembly ).
Air Cleaner Assembly Installation
<6G7> (Refer to ).
Engine Cover Installation (Refer
to GROUP 11C - Engine
Assembly ).
Engine Coolant Refilling (Refer to
GROUP 14 - On-vehicle Service,
Engine Coolant Replacement ).
Fuel Leak Check

Removal
steps
1. Purge
control
solenoid
valve
connector
2. Purge
control
solenoid
valve
3. Manifold
absolute
pressure
sensor
connector
4. Manifold
absolute
pressure
sensor
5. O-ring
6. Noise
condenser
connector
7. Noise
condenser
8. Variable
induction
control
solenoid
valve
connector
9. Control
wiring
harness and
detonation
sensor
wiring
harness
combination
connector
10. Detonation
sensor
wiring
harness
connector
11. Control
wiring
harness and
injector
wiring
harness
(L.H.)
combination
connector
12. Injector
wiring
harness
(L.H.)
connector
13. Earth cable
14. Harness
clamp
15. Harness
bracket
16. Control
wiring
harness and
injector
wiring
harness
(R.H.)
combination
connector
17. Injector
wiring
harness
(R.H.)
connector
18. Vacuum
hose
connection
19. Fuel vapour
control hose
20. Emission
vacuum
control
chamber
21. Fuel vapour
control hose
22. Fuel vapour
control hose
connection
23. Emission
vacuum
pipe
24. Emission
control
equip hose
25. Emission
vacuum
hose
26. Emission
control
vacuum
tank
27. Emission
control
equip hose
28. Variable
induction
control
solenoid
valve
assembly
29. Emission
vacuum
hose
30. Emission
vacuum
hose
31. PCV hose
connection
 32. Emission
vacuum
pipe
33. EGR pipe
assembly
>>E<< 34. EGR pipe
gasket
35. Surge tank
stay
<<A>> >>D<< 36. Surge tank
assembly
>>D<< 37. Surge tank
gasket
38. Engine air
intake surge
tank
39. Intake
manifold
tuning valve
gasket S
40. Intake
manifold
tuning valve
gasket P
41. Harness
bracket
 Removal
steps
<<B>> >>C<< 42. Fuel high-
pressure
hose
connection
43. Cooling
water line
hose
connection
44. Cooling
water line
hose
connection
45. Injector
connector
<<C>> 46. Fuel
delivery
pipe, fuel
high-
pressure
hose and
injector
assembly
47. Oil pipe
connection
>>B<< 48. Inlet
manifold
>>A<< 49. Inlet
manifold
gasket

REMOVAL SERVICE POINTS

<<A>> SURGE TANK ASSEMBLY

REMOVAL

If the clearance is too narrow when removing the surge

tank, jack up the transmission assembly to secure a
working space.

<<B>> FUEL HIGH-PRESSURE

HOSE DISCONNECTION
 1.
caution Do not kink the fuel high-pressure
hose as it is made of plastics.
Insert a flat-tipped screwdriver (width 6 mm, thickness
1 mm) to the retainer.
2.Turn the flat-tipped screwdriver approximately 90° to
the arrowed direction, and lift the retainer to unlock and
disconnect the fuel high-pressure hose.

<<C>> FUEL DELIVERY PIPE,

FUEL HIGH-PRESSURE HOSE AND
FUEL INJECTOR ASSEMBLY
REMOVAL

caution Do not drop the fuel injector.

Remove the fuel delivery pipe and fuel high-pressure hose
with the fuel injector assembly attached to it.

INSTALLATION SERVICE POINTS

>>A<< INLET MANIFOLD GASKET

INSTALLATION

Install the inlet manifold gasket with the protrusions in

the position illustrated.

>>B<< INLET MANIFOLD

INSTALLATION
 Tighten the inlet manifold mounting nuts by the
following procedure.
Order Mounting Tightening
nuts torque
1st Right 6.5 ± 1.0
bank nuts N·m
2nd Left bank 22 ± 1 N·m
nuts
3rd Right 22 ± 1 N·m
bank nuts
4th Left bank 22 ± 1 N·m
nuts
5th Right 22 ± 1 N·m
bank nuts

>>C<< FUEL HIGH-PRESSURE

HOSE CONNECTION

1.Pull up the lock of fuel high-pressure hose to unlock

before installing.
2.Install the fuel high-pressure hose to the delivery pipe
securely and push the lock of fuel high-pressure hose
downward and lock thoroughly.
3.After installing, slightly pull the fuel high-pressure
hose and ensure that there is no disengaged fuel high-
pressure hose. Also confirm that there is
approximately 1 mm play at this time.

>>D<< SURGE TANK

GASKET/SURGE TANK ASSEMBLY
INSTALLATION
 1.Temporarily install the positioning bolt for the surge
tank gasket (M8×1.25 mm, length 25 mm) to the
position shown in the figure from under side.
2.Install the surge tank gasket with the protrusions in
the position illustrated.
3.Install the surge tank assembly taking care not to let
the surge tank gasket deviate from its position.
4.Remove the positioning bolt for surge tank gasket
that was temporarily installed in step 1.

>>E<< EXHAUST MANIFOLD EGR

PIPE GASKET INSTALLATION

Install the exhaust manifold EGR pipe gasket as its

protrusion is in the direction shown.
REMOVAL AND INSTALLATION <6G72>

Pre-removal Operation Post-installation Operation

Fuel Line Pressure Reduction [Refer to GROUP 13A -
On-vehicle Service, Fuel Pump Connector
Disconnection (How to Reduce Pressurized Fuel
Lines) ].
Engine Coolant Draining (Refer to GROUP 14 - On-
vehicle Service, Engine Coolant Replacement ).
Battery and Battery Tray Removal (Refer to GROUP
54A - Battery ).
A/T Fluid Level Gauge and Guide assembly Removal
(Refer to GROUP 11A - Engine Oil Pan ) <A/T>.
Engine Oil Level Gauge and Guide assembly
Removal (Refer to GROUP 11A - Engine Oil Pan ) .
Air Cleaner Assembly Removal <6G7> (Refer to ).
Throttle Body Assembly Removal (Refer to GROUP
13A - Throttle Body Assembly ).
EGR Valve Removal <6G72> (Refer to GROUP 17 -
Emission Control, EGR Valve ).
EGR Pipe Removal (Refer to ).
Fuel High-pressure Tube Removal (Refer to GROUP
11A - Engine Assembly ).
Fuel High-pressure Tube
Installation (Refer to GROUP 11A -
Engine Assembly ).
EGR Pipe Installation (Refer to ).
EGR Valve Installation <6G72>
(Refer to GROUP 17 - Emission
Control, EGR Valve ).
Throttle Body Assembly Installation
(Refer to GROUP 13A - Throttle
Body Assembly ).
Air Cleaner Assembly Installation
<6G7> (Refer to ).
Engine Oil Level Gauge and Guide
assembly Installation (Refer to
GROUP11A - Engine Oil Pan ) .
A/T Fluid Level Gauge and Guide
assembly Installation (Refer to
GROUP11A - Engine Oil Pan )
<A/T>.
Battery and Battery Tray
Installation (Refer to GROUP 54A -
Battery ).
Engine Coolant Refilling (Refer to
GROUP 14 - On-vehicle Service,
Engine Coolant Replacement ).
Fuel Leak Check

Removal
steps
1. Control
harness
connection
2. Earth cable
connection
3. PCV hose
connection
4. Fuel purge
hose
connection
<Vehicles
with
canister>
5. Free wheel
clutch
vacuum hose
connection
6. Purge
solenoid
valve,
vacuum hose
and vacuum
pipe
assembly
<Vehicles
with
canister>
7. EGR
solenoid
valve and
vacuum hose
assembly
8. Harness
bracket
9. Manifold
absolute
pressure
sensor
10. O-ring
11. Air intake
fitting
12. Air intake
fitting gasket
13. Harness
bracket
14. Detonation
sensor,
camshaft
position
sensor
connector
bracket
15. Fuel injector
harness
connector
bracket
16. Noise
condenser
17. Water outlet
fitting
bracket
18. Surge tank
stay
 19. Upper inlet
manifold
>>E<< 20. Surge tank
gasket
Removal
steps
21. Fuel
injector
harness
connection
<<A>> >>D<< 22. Fuel
delivery
pipe, fuel
high-
pressure
tube and
fuel
injector
assembly
23. Insulator
>>C<< 24. O-ring
25. Water
hose
connection
26. Harness
clamp
>>B<< 27. Inlet
manifold
>>A<< 28. Inlet
manifold
gasket

REMOVAL SERVICE POINT

<<A>> FUEL DELIVERY PIPE,

FUEL HIGH-PRESSURE TUBE AND
FUEL INJECTOR ASSEMBLY
REMOVAL

caution Do not drop the fuel injector.

Remove the fuel delivery pipe and fuel high-pressure tube
with the fuel injector assembly attached to it.
INSTALLATION SERVICE POINTS

>>A<< INLET MANIFOLD GASKET

INSTALLATION

Install the inlet manifold gasket with the protrusions in

the position illustrated.

>>B<< INLET MANIFOLD

INSTALLATION

Tighten the inlet manifold mounting nuts by the

following procedure.
Order Mounting Tightening
nuts torque
1st Right 6.5 ± 1.0
bank nuts N·m
2nd Left bank 22 ± 1 N·m
nuts
3rd Right 22 ± 1 N·m
bank nuts
4th Left bank 22 ± 1 N·m
nuts
5th Right 22 ± 1 N·m
bank nuts

>>C<< O-RING INSTALLATION

1.Apply a drop of new engine oil to the O-ring.

2.Using special tool O-ring installer (MB992106),
install the O-ring to the fuel injector paying attention to
avoid damage to the O-ring.

>>D<< FUEL DELIVERY PIPE,

FUEL HIGH-PRESSURE TUBE AND
FUEL INJECTOR ASSEMBLY
INSTALLATION
1.
caution Do not let the engine oil get into the
inlet manifold.
Apply a small amount of new engine oil to the O-ring at the
tip of the fuel injector.

2.
When installing the fuel delivery pipe,
fuel high-pressure tube and fuel injector
caution assembly to the inlet manifold, take
care not to damage the O-ring at the tip
of the fuel injector assembly.
Install the fuel delivery pipe, fuel high-pressure tube and fuel
injector assembly to the inlet manifold.

>>E<< SURGE TANK GASKET

INSTALLATION

Install the surge tank gasket with the protrusions in the

position illustrated.
REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation

Air Cleaner Assembly Removal and Installation <4M4> (Refer to ).
Under Skid Plate and Engine Room Under Cover (Front) Removal and Installation (Refer to
GROUP 51 - Under Cover ).
Radiator Shroud Cover Removal and Installation (Refer to GROUP 14 - Radiator ).

Removal
steps
1. Intercooler
air hose
A1
2. Intercooler
air hose B
3. Intercooler
air hose
A2
<<A>> >>A<< 4. Intercooler
assembly
5. Deflector
plate
6. Intercooler
air pipe

REMOVAL SERVICE POINT

<<A>> INTERCOOLER REMOVAL

1.
When moving the stabilizer bar to the
position where it will not interfere with
caution the intercooler removal, be careful not
to damage the ball joint section of the
stabilizer link.
Before removing the intercooler, remove the clamp of the
stabilizer bar, and move the stabilizer bar to the position
where it will not interfere with the intercooler removal.
(Refer to GROUP 33 - Stabilizer Bar ).
2.After removal of the intercooler, return the stabilizer bar to
the original position, and install the clamp temporarily.
INSTALLATION SERVICE POINT

>>A<< INTERCOOLER
INSTALLATION

1.
When moving the stabilizer bar to the
position where it will not interfere with
caution the intercooler installation, be careful
not to damage the ball joint section of
the stabilizer link.
Before installing the intercooler, remove the clamp of the
stabilizer bar, which was installed temporarily, and move
the stabilizer bar to the position where it will not interfere
with the intercooler installation.
2.After removal of the intercooler, return the stabilizer bar to
the original position, and install the clamp. (Refer to
GROUP 33 - Stabilizer Bar ).
REMOVAL AND INSTALLATION <4M4>

Removal steps
1. Air intake duct
2. Pre-air cleaner
3. Breather hose
connection
4. Air intake hose
5. Air flow sensor
connector <4M41>
6. Air cleaner
assembly
7. Air flow sensor
<4M41>
8. Air cleaner cover
9. Air cleaner element
10. Air cleaner body
11. Air cleaner bracket
REMOVAL AND INSTALLATION <6G7>

Removal steps
1. Air intake duct A
2. Air intake duct B or
pre-air cleaner
3. Breather hose
connection
4. Air intake hose
5. Air cleaner
resonator
6. Air flow sensor
connector
7. Air cleaner
assembly
8. Air flow sensor
9. Air flow sensor
support
10. Gasket
11. Air cleaner cover
12. Air cleaner element
13. Air cleaner body
14. Air cleaner bracket
VARIABLE INDUCTION CONTROL SYSTEM
CHECK <6G75>
1.Warm up the engine.
2.Disconnect the vacuum hose from the vacuum
actuator, and then connect a vacuum gauge via the
three-way joint.
3.Start the engine and verify that a vacuum is applied
to the vacuum gauge.
4.As described in the chart below, vary the engine
speed to inspect the vacuum conditions. During this
inspection, verify that the rod of the vacuum actuator is
operating.
Engine Normal Vacuum
speed condition actuator
rod
Idling Barometric Extended
pressure
Suddenly Temporary Temporarily
raced vacuum shorten
state
WASTE GATE ACTUATOR CHECK <4M4>
1.Connect a manual pump (pressure-application type)
to nipple.
In order to avoid damage to the diaphragm,
caution do not apply a pressure of 115 kPa
<4M40> 153 kPa <4M41> or higher.
2.While gradually applying pressure, check the
pressure that begins to activate (approximately 1 mm
stroke) the waste gate actuator rod.
Standard value:
Approximately 96 kPa <4M40>kPa
118.8 - 124.2 kPa <4M41>
3.If there is a significant deviation from the standard
value, check the actuator or the waste gate valve:
replace actuator or turbocharger assembly if
necessary.
TURBOCHARGER SUPERCHARGING
PRESSURE CHECK <4M41>
1.
Conduct the driving test in a location
where driving at full acceleration can
be done with safety. Two person
caution should be in the vehicle when the test is
conducted; the person in the
passenger seat should read the
indications shown by the M.U.T.-III.
Set the vehicle to the pre-inspection condition.
2.Turn the ignition switch to "LOOK" (OFF) position,
and connect the diagnosis connector to the M.U.T.-III.
3.Use the data list function named "Item No. 6" boost
pressure sensor of the M.U.T.-III to check the
supercharging pressure when the engine speed
increases to approximately 3,000 r/min or more by
driving at full acceleration in 2nd.
Standard value: 178.9 - 188.2 kPa
4.If the supercharging pressure deviates from the
standard value, check the following items for possible
cause.

Malfunction of the waste gate actuator

Malfunction of the boost pressure sensor
Leakage of supercharging pressure
Malfunction of the turbocharger
5.When the indicated supercharging is more than
standard value, supercharging control may be faulty,
therefore check the followings.

Disconnection or cracks of the waste gate

actuator rubber hose
Malfunction of the waste gate actuator
Malfunction of the waste gate valve
Malfunction of the manifold absolute pressure
sensor
SPECIAL TOOLS
Tool Number Name Use
MB991955 M.U.T.-III sub Measurement of turbocharger supercharging
A: assembly pressure <4M41>
MB991824 For vehicles with CAN communication,
B: use M.U.T.-III main harness A to send
MB991827 A: Vehicle simulated vehicle speed. If you connect
C: communication caution M.U.T.-III main harness B instead, the
MB991910 interface CAN communication does not function
D: (V.C.I.) correctly.
MB991911 B: M.U.T.-III
E: USB cable
MB991825 C: M.U.T.-III
F: main harness
MB991826 A (Vehicles
with CAN
communication
system)
D: M.U.T.-III
main harness
B (Vehicles
without CAN
communication
system)
E: M.U.T.-III
measurement
adapter
F: M.U.T.-III
trigger harness

MB991953 Oxygen sensor Removal and installation of oxygen sensor <6G7>

wrench
SERVICE SPECIFICATIONS
Item Standard Limit
value
Variable induction control solenoid valve coil resistance (at 20 °C) <6G75> Ω 29 - 35 -
Turbocharger supercharging pressure <4M41> kPa 178.9 - 188.2 -
Initial activation pressure of waste gate actuator (at the stroke of 4M40 Approximately -
approximately 1 mm) kPa 96
4M41 118.8 - 124.2 -
Swirl control solenoid valve coil resistance (at 20 °C) <4M41> Ω 29 - 35 -
Inlet manifold distortion of the installation surface <6G7, 4M41>mm 0.15 or less 0.20
Exhaust manifold distortion of the installation surface <6G7> mm 0.5 or less 0.90
Exhaust manifold distortion of the installation surface <4M41> mm 0.15 or less 0.20
GENERAL INFORMATION
The exhaust pipe is divided into five parts <6G7, 4M41> or four parts <4M40>.