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    General Information: Intake and Exhaust

    Uploaded by

    احمدميدو
    The document provides information on intake and exhaust components for a vehicle. It includes sections on the intake manifold, air cleaner, intake manifold plenum, intake manifold, exhaust manifold, exhaust pipe, and main muffler. Specifications and removal/installation procedures are provided for servicing each component. Special tools needed include an oxygen sensor wrench.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    General Information: Intake and Exhaust

    Uploaded by

    احمدميدو
    20 views8 pages
    The document provides information on intake and exhaust components for a vehicle. It includes sections on the intake manifold, air cleaner, intake manifold plenum, intake manifold, exhaust manifold, exhaust pipe, and main muffler. Specifications and removal/installation procedures are provided for servicing each component. Special tools needed include an oxygen sensor wrench.

    Original Description:

    gbn

    Original Title

    9915p29

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    © © All Rights Reserved

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    The document provides information on intake and exhaust components for a vehicle. It includes sections on the intake manifold, air cleaner, intake manifold plenum, intake manifold, exhaust manifold, exhaust pipe, and main muffler. Specifications and removal/installation procedures are provided for servicing each component. Special tools needed include an oxygen sensor wrench.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    20 views8 pages

    General Information: Intake and Exhaust

    Uploaded by

    احمدميدو
    The document provides information on intake and exhaust components for a vehicle. It includes sections on the intake manifold, air cleaner, intake manifold plenum, intake manifold, exhaust manifold, exhaust pipe, and main muffler. Specifications and removal/installation procedures are provided for servicing each component. Special tools needed include an oxygen sensor wrench.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 8

    INTAKE AND EXHAUST

    General Information/Service Specifications/Special tool

    Main
    Index

    GENERAL INFORMATION
    The intake manifold is made of an aluminium alloy,
    and the shape provides an increased intake inertia
    effect and has a good volumetric efficiency.

    The exhaust pipe is divided into four parts.

    15
    Index

    SERVICE SPECIFICATIONS
    Items
    Intake manifold

    Distortion of the installation surface mm

    Standard value

    Limit

    0.15 or less

    0.2

    SPECIAL TOOL
    Tool

    Tool number and name

    Supersession

    Application

    MD998770
    Oxygen sensor wrench

    Removal/Installation of oxygen
    sensor <Vehicles with catalytic
    converter>

    ON-VEHICLE SERVICE
    INTAKE MANIFOLD VACUUM CHECK
    Refer to Group 11 On-vehicle Service

    INTAKE AND EXHAUST Air Cleaner


    Main
    Index

    AIR CLEANER
    REMOVAL AND INSTALLATION

    15
    Index
    9 Nm

    10

    4 Nm

    11

    9 Nm

    2
    9

    6
    9 Nm

    1
    5

    9 Nm
    4 Nm

    Removal steps
    1. Air cleaner element
    2. Breather hose
    3. Air flow sensor
    4. Gasket
    5. Air cleaner cover
    6. Air intake hose assembly

    7.
    8.
    9.
    10.
    11.

    Resonator A
    Resonator B
    Air intake hose
    Air duct
    Air cleaner body

    INTAKE AND EXHAUST Intake Manifold Plenum


    Main
    Index

    INTAKE MANIFOLD PLENUM


    REMOVAL AND INSTALLATION
    Pre-removal Operation
    (1) Remove the engine cover (Refer to GROUP 11B
    Intake manifold plenum and throttle body)
    (2) Remove the throttle body (Refer to GROUP 13A
    Fuel)
    (3) Drain the power steering fluid
    (Refer to GROUP 37 On-vehicle service)

    Post-installation Operation
    (1) Install the throttle body (Refer to GROUP 13A
    Fuel)
    (2) Install the engine cover (Refer to GROUP 11B
    Intake manifold plenum and throttle body.)
    (3) Add power steering fluid and bleed
    (Refer to GROUP 37 On-vehicle service.)
    (4) Adjust the tension of the oil pump belt (Refer to
    GROUP 11A On-vehicle service.)

    18 Nm
    1012

    13

    18 Nm

    10 Nm

    18 Nm

    39 Nm

    18 Nm

    5
    24 Nm

    13
    10

    3
    2

    7
    22 Nm

    11

    35 Nm

    9
    49 Nm

    Removal steps
    1. Crank angle sensor connector
    2. EGR valve assembly
    3. Brake booster vacuum hose
    connection
    4. EGR pipe assembly connection
    5. Fuel pressure regulator vacuum
    hose connection
    6. Oil pump belt

    "BA 7.
    8.
    9.
    10.
    11.
    12.
    "AA 13.

    Pressure hose
    Power steering
    Pump bracket
    Intake manifold
    Intake manifold
    Intake manifold
    Intake manifold

    24 Nm

    oil pump
    plenum stay, front
    plenum stay, rear
    plenum
    plenum gasket

    15
    Index

    INTAKE AND EXHAUST Intake Manifold Plenum

    INSPECTION

    Main
    Index

    INTAKE MANIFOLD PLENUM


    1. Check that the intake manifold plenum is not damaged
    15
    or cracked.
    2. Check that the vacuum extraction port is not clogged. Index
    If faulty, clean.
    3. Using a straight edge and thickness gauge, check the
    mounting surface for distortion.
    Standard value: 0.15 mm or less
    Limit: 0.2 mm

    INSTALLATION SERVICE POINT


    "AA INTAKE MANIFOLD PLENUM GASKET
    Install so that the projection on the gasket is as shown in
    the diagram.

    Front
    Projection

    Eye joint
    notched part

    Suction
    connector

    "BA PRESSURE HOSE


    Secure the notched part of the pressure hose eye joint at
    the position where it contacts the oil pump suction connector.

    INTAKE AND EXHAUST Intake Manifold


    Main
    Index

    INTAKE MANIFOLD
    REMOVAL AND INSTALLATION

    15
    Index

    Pre-removal and Post-Installation Operations


    D Remove or install the intake manifold plenum
    (Refer to P.15-4.)
    D Fuel discharge prevention (Refer to GROUP.13
    On-vehicle service)

    12 Nm

    5
    12 Nm

    1
    4
    5 Nm

    20 - 23 Nm

    2
    24 Nm

    3
    20 - 23 Nm

    10 - 12 Nm

    9
    7

    8
    Intake
    manifold
    mounting
    stud

    Cylinder
    head
    Engine oil

    O-ring
    Engine oil

    Removal steps
    1. Injector connector
    "CA 2. Fuel high pressure hose connection
    3. Return hose connection
    4. Vacuum hose connection
    AA"
    5. Injector and delivery pipe assembly

    6.
    7.
    "BA 8.
    "AA 9.

    PCV hose connection


    Timing belt cover(Front upper)
    Intake manifold
    Intake manifold gasket

    REMOVAL SERVICE POINT


    AA" INJECTOR AND DELIVERY PIPE ASSEMBLY
    Remove the delivery pipe with the injectors fitted to the delivery
    pipe.
    Caution
    Do not drop the injectors when removing the delivery
    pipe.

    INTAKE AND EXHAUST Intake Manifold


    Main
    Index

    INSPECTION

    INTAKE MANIFOLD
    1. Check that the intake manifold is not damaged or cracked.
    15
    If faulty, replace.
    2. Check that the vacuum extraction port is not clogged. Index
    If faulty, clean.
    3. Using a straight edge and thickness gauge, check the
    mounting surface for distortion.
    Standard value: 0.15 mm or less
    Limit: 0.2 mm

    INSTALLATION SERVICE POINT

    Front

    Projection

    "AA INTAKE MANIFOLD GASKET


    Install so that the projection on the gaskets is as shown in
    the diagram.

    Projection

    "BA INTAKE MANIFOLD


    1. Coat the intake manifold mounting studs with engine oil.
    2. Tighten the intake manifold mounting nuts in the following
    sequence.

    Left bank side


    Right bank side

    Intake manifold

    Sequence

    Tightening nuts

    Tightening Torque
    Nm

    Left bank side nuts

    Right bank side nuts

    20 to 23

    Left bank side nuts

    20 to 23

    Right bank side nuts

    20 to 23

    Left bank side nuts

    20 to 23

    INSTALLATION SERVICE POINT


    5 Nm
    Fuel
    pressure
    hose

    "CA FUEL HIGH PRESSURE HOSE CONNECTION


    1. When connecting the high-pressure fuel hose to the fuel
    rail, apply a drop of new engine oil to the O-ring, and
    then insert, being careful not to damage the O-ring.
    Caution
    Do not let engine oil in the fuel rail.

    Fuel rail
    O-ring

    5 Nm

    2. Check that the high-pressure fuel hose turns smoothly.


    If not, remove the hose and then re-insert it into the fuel
    rail and check again.
    3. Tighten the bolts to the specified torque.

    INTAKE AND EXHAUST Exhaust Manifold


    Main
    Index

    EXHAUST MANIFOLD
    REMOVAL AND INSTALLATION

    15
    Index

    Pre-removal and Post-Installation Operations


    D Remove or install the front exhaust pipe (Refer
    to P.15-9.)
    D Remove or install the radiator (Front bank only)
    (Refer to GROUP.14)
    D Remove or install the alternator (Front bank only)
    (Refer to GROUP.16)

    13 Nm

    6
    1
    19 Nm

    5
    59 Nm

    29 Nm

    2
    29 Nm

    13 Nm

    8
    7
    4

    Removal Procedure for Front Bank


    1. Heat protector
    2. Exhaust manifold
    3. Exhaust manifold gasket

    Removal Procedure for Rear Bank


    4. Heat protector
    5. EGR pipe
    6. EGR pipe gasket
    7. Exhaust manifold
    8. Exhaust manifold gasket

    INTAKE AND EXHAUST Exhaust Pipe and Main muffler


    Main
    Index

    EXHAUST PIPE AND MAIN MUFFLER


    REMOVAL AND INSTALLATION
    18

    15
    Index

    11

    49 Nm
    44 Nm

    17

    7 Nm

    14

    17
    15
    16

    13 Nm

    12

    13

    49 Nm
    13 Nm
    13 Nm
    13 Nm

    <SEDAN>

    4
    9

    34 Nm

    5
    10

    49 Nm

    13 Nm

    1
    3

    9
    13 Nm
    13 Nm

    <WAGON>

    4
    6
    13 Nm

    34 Nm

    49 Nm

    10
    Main muffler removal steps
    1. Hanger
    2. Main muffler assembly
    3. Hanger bracket
    4. Gasket
    5. Rear floor heat protector panel
    Centre exhaust pipe removal steps
    6. Hanger
    7. Centre exhaust pipe
    8. Gasket
    9. Damper

    10. Hanger bracket


    11. Harness protector
    12. Catalytic converter or pre-muffler
    13. Gasket
    Front exhaust pipe removal steps
    14. Oxygen sensor
    15. Hanger
    16. Front exhaust pipe
    17. Gasket
    18. Front floor heat protector

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