Page 729 of 2103
12 Nm8.7
q 26
3.6
9.8 Nm7.2
3 . 6
24. Fuel rail, fuel injector and pressureregulator assembly25. Insulator
26. Insulator
27. Manifold erential pressure sensor26. Ignition power transistor29. Spark plug cable connection
TSB Revision
30.Ignition coil
31. Intake manifold stay
32.Intake manifold33. Intake manifold gasket34. Throttle body35. EGR valve assembly
Page 730 of 2103

INTAKE AND EXHAUST Intake Manifold
REMOVAL SERVICE POINTS
HIGH-PRESSURE FUEL HOSE DISCONNECTION
Relieve pressure in the fuel pipe line to prevent fuel outflow.
(Refer to GROUP On-vehicle Service.)
Caution
Cover fuel pipe line with shop towel after relievin g pres-
sure as certain pressure may
remain.
RAIL, FUEL INJECTOR AND PRESSURE
REGULATOR ASSEMBLY REMOVAL
Remove fuel rail with fuel injector and pressure re gulator
attached.
Caution
Do not drop fuel injector when removing fuel rail.
INSTALLATION POINT,
HIGH-PRESSURE FUEL HOSE
When connecting the hose to the fuel rail,
apply a, small amount of new engine the hose union,
and then insert, being careful not to damage the O- ring.
C a u t i o n Do not let engine oil get into
fuel rail.
.
I N S P E C T I O N 15100310123
Check the following points; the part if is
found. .
INTAKE MANIFOLD CHECK 1. Check for damage or cracking of any part.
2.Check for obstruction of the negative pressure (vac uum)
outlet port, and for obstruction of the water passage or
gas passage.
3.Using a straight edge and a feeler gauge, check for distor-
tion of the cylinder head installation surface.
Standard value: 0.15 mm
in.) or less
Limit: 0.2 mm
in.)
TSB Revision
Page 731 of 2103
INTAKE, AND EXHAUST Exhaust Manifold Engine
EXHAUST MANIFOLD ENGINE (NON-TURBO)>’
REMOVAL AND INSTALLATION
and Post-installation Operationl Engine Coolant Draining and (Refer to GROUP
3.9 Nm2.9
6
Removal steps
1. Air intake hose
2. Radiator upper hose connection
3. Air hose connection
4. Control wiring harness connection
5. Water pipe assembly
6. Engine oil level gauge
Nm
44Nm33
,
7.Heat protector6.Engine hanger9. Front exhaust connection10.Heatprotector11. Exhaust 12. Exhaust manifold gasket
TSB RevisionI
Page 732 of 2103
INTAKE AND EXHAUST Exhaust Manifold
E X H A U S T M A N I F O L D E N G I N E ( T U R B O ) >
REMOVAL AND INSTALLATION
Pre-removal and Post-installation OperationEngine Coolant Draining and Refilling
l Engine Oil Draining and Refilling
(Refer to GROUP 00
Maintenance Service.)
Nm
12-15 Nm8.8-11- - 1 6 ’
3
. .
Removal steps
1. Condenser fan motor assembly with air conditioning>
2. Heated oxygen sensor
3. Engine oil level gauge guide
4. Air cleaner and air intake hose
assembly5. Air hose (A) connection
6. Water hose connection
7. Water hose connection
8. Oil pipe (A) connection 9. Heat protector
A)
10. Heat protectorB)
11. Engine hanger
12. Front exhaust pipe connection 13. Flange bolts 14. Flange 15.
Coned disc spring .16. Exhaust -manifold17.Exhaust manifold gasket Ring19. Gasket (A)
TSB Revision
Page 733 of 2103
INTAKE AND EXHAUST Exhaust Manifold
24 ,
54-64 Nm
20. Vacuum hose assembly 21. Turbocharger assembly22. Oil return pipe
23. Water pipe assembly (B) 24. Oil pipe 25. Water pipe assembly (A)
26. manifold fitting27.Ghsket
REMOVAL SERVICE
HEATED OXYGEN SENSOR REMOVAL
TSB Revision
TURBOCHARGER ASSEMBLY
Remove the turbocharger
assembly with the exhaust fitting,
water pipe assembly (A), water pipe assembly (B) an d the
oil pipe assembly attached to it.
OIL PIPE ASSEMBLY REMOVAL
Caution
After disconnecting the oil pipe, take care that fo reign
materialdoesnotenter the oil passage hole of the turbo-
charger assembly.
Page 734 of 2103

INTAKE AND EXHAUST Exhaust Manifold ENGINE (Turbo)>
Identification holeExhaust
manifold
INSTALLATION SERVICE POINTS
TURBOCHARGER ASSEMBLY
(1) Clean the alignment surfaces shown in the illus tration.
(2) Supply clean engine oil through the oil pipe in stallation
hole of the turbocharger assembly.
Caution
When cleaning, take care that no foreign material g ets
into the engine coolant or oil passages hole.
CONED DISC SPRING/FLANGE NUT/FLANGE
BOLTS INSTALLATION
(1) Install the coned disc spring the shown direction.
(2) Tighten the flange nuts and bolts to 27
31 Nm (20
23
(3) Use the special tool to further tighten by
INSPECTION
TURBOCHARGER ASSEMBLY CHECK . .
1. Visually check the turbine wheel and
wheel for cracking or other damage.
2. Check whether the turbine wheel and
compressor
wheel can be easily turned by
3. Check for oil leakage from the turbocharger asse mbly.
4.Check if the turbocharger waste gate valve remains open.
If any problem is found, replace the part
.
OIL PIPE ASSEMBLY AND OIL-RETURN PIPE
Check the oil pipe assembly and oil-return pipe for clogging,
bending, or other damage. If there is clogging, clea n it.
TSB Revision
Page 735 of 2103
INTAKE AND EXHAUST Exhaust Manifold
EXHAUST MANIFOLD ENGINE>
,
REMOVAL AND INSTALLATION
, .
12-15 Nm29 Nm21
49 Nm36
Removal steps
1. Front exhaust connection2.Gasket3.Heat protector4.Engine hanger5.Exhaust manifold6. Exhaust manifold gasketITSB Revision
Page 736 of 2103
INTAKE AND EXHAUST Exhaust Pipe and Main Muffler
EXHAUST PIPE AND MAIN MUFFLER
REMOVAL AND INSTALLATION
Engine (Non-turbo)>
and Post-installationlUnder Cover Removal and Installation
(Refer to GROUP Cover.)
18
9.4 ,
4936,8I
6
9.4
9.4
Main muffler removal steps Catalytic converter removal steps
1. Main muffler assembly2. Gasket13. Catalytic 14. Gasket
3. Hanger
4. Tail hanger15. Catalytic converter bracket
5. Rear hanger16. Hanger protector
6. Rear floor heat protector panel17. Hanger18. Front hanger
Center exhaust pipe removal steps
7. Heated oxygen sensor connection
exhaust pipe
Hanger protector11. Hanger
12. Hanger bracket
TSB Revision
19. Front floor heat protector panel
Front pipe steps
20. connection
21. Front exhaust:22. Gasket