Page 1697 of 2771
EM-20
< SERVICE INFORMATION >
INTAKE MANIFOLD
3. Tighten intake manifold bolt (A). Then tighten intake manifold
bolt (B).
4. Install electronic throttle control actuator
5. Install water hoses (3), (5) to electronic throttle control actuator
as shown.
6. Installation of the remaining components is in the reverse order of removal.
INSPECTION AFTER INSTALLATION
• Check for leaks of engine coolant. Refer to CO-8, "Inspection".
• Start and warm up the engine. Visually check for engine coolant leaks.
1 : Intake manifold
: Engine front
PBIC3939E
1 : Electronic throttle control actuator
2: Clamp
4 : Water outlet
A: Paint Mark
B : The clamp shall not interfere with the bulged section.
PBIC4703E
Page 1698 of 2771
EXHAUST MANIFOLD
EM-21
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EXHAUST MANIFOLD
ComponentINFOID:0000000001702485
Removal and InstallationINFOID:0000000001702486
REMOVAL
1. Remove exhaust front tube. Refer to EX-4, "Removal and Installation".
2. Remove exhaust manifold cover.
3. Remove the A/F sensor 1, using Tool (A).
CAUTION:
Handle it carefully and avoid impacts.
4. Remove exhaust manifold side bolt of exhaust manifold stay.
1. Exhaust manifold cover 2. Exhaust manifold 3. Gasket
4. Stud bolt 5. Bracket 6. A/F ratio sensor 1
7. Exhaust manifold stay Engine front
WBIA0778E
Tool number :KV991J0050 (J-44626)
WBIA0772E
Page 1699 of 2771
EM-22
< SERVICE INFORMATION >
EXHAUST MANIFOLD
5. Loosen nuts in reverse order as shown and remove exhaust
manifold.
CAUTION:
Cover engine openings to avoid entry of foreign materials.
INSPECTION AFTER REMOVAL
Surface Distortion
• Using straightedge (B) and feeler gauge (A), check the surface dis-
tortion of exhaust manifold mating surface in each exhaust port
and entire part.
• If it exceeds the limit, replace exhaust manifold.
INSTALLATION
1. Install exhaust manifold gasket to cylinder head as shown.
2. Tighten exhaust manifold nuts to specification in two stages in
the numerical order as shown.
: Engine front
PBIC3529J
Limit:
Each exhaust port : 0.3 mm (0.012 in)
Entire part : 0.7 mm (0.028 in)
PBIC3530J
: Engine front
PBIC3943E
: Engine front
PBIC3529J
Page 1700 of 2771
EXHAUST MANIFOLD
EM-23
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3. Install exhaust manifold stay (2) in the direction as shown.
4. Install the A/F ratio sensor 1, using Tool
CAUTION:
• Handle it carefully and avoid impacts.
• Before installing a new A/F ratio sensor, clean the exhaust
tube threads using suitable tool and approved anti-seize
lubricant.
• Do not over-tighten the A/F ratio sensor. Doing so may
damage the A/F ratio sensor, resulting in the MIL coming
on.
5. Installation of the remaining parts is in the reverse order of removal.
1 : Exhaust manifold
A : Upper mark
: Engine front
PBIC3944E
Tool number : KV991J0050 (J-44626)
Tool number : — (J-43897-12)
Tool number : — (J-43897-18)
WBIA0772E
Page 1701 of 2771
EM-24
< SERVICE INFORMATION >
OIL PAN
OIL PAN
ComponentINFOID:0000000001702487
Removal and InstallationINFOID:0000000001702488
REMOVAL
WARNING:
• Be careful not to burn yourself, as the engine oil is hot.
• Prolonged and repeated contact with used engine oil may cause skin cancer; try to avoid direct skin
contact with used oil. If skin contact is made, wash thoroughly with soap or hand cleaner as soon as
possible.
1. Oil level gauge 2. Oil level gauge guide 3. Rear oil seal
4. O-ring 5. Oil pan (upper) 6. Oil pump drive chain
7. Crankshaft sprocket 8. Oil pump sprocket 9. Timing chain tensioner (for oil pump)
10. Oil pump 11. Drain plug 12. Drain plug washer
13. Oil pan (lower) 14. Oil filter 15. Connector bolt
16. O-ring
A. Refer to EM-24
: Oil pan side
PBIC4482E
Page 1702 of 2771
OIL PAN
EM-25
< SERVICE INFORMATION >
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1. Drain engine oil. Refer to LU-6.
2. Remove engine and transaxle assembly. Refer to EM-72
.
3. Remove oil filter using Tool.
CAUTION:
When removing, prepare a shop cloth to absorb any engine oil leakage or spillage.
4. Remove oil pan (lower) bolts in reverse order as shown.
5. After removing the bolts and nuts, separate the mating surface
and remove the sealant using Tool.
CAUTION:
Be careful not to damage the mating surfaces.
6. Remove the following parts:
• Flywheel (M/T models) or drive plate (A/T or CVT models); Refer to EM-76
.
• Front cover, timing chain, oil pump drive chain; Refer to EM-37
.
7. Remove oil pump.
• Loosen bolts in reverse order as shown.
8. Remove oil pan (lower) bolts in reverse order as shown.Tool number : KV10115801 ( — )
: Engine front
PBIC3146J
Tool number : KV10111100 (J-37228)
WBIA0566E
1: Oil pump
2 : Oil pan (upper)
: Engine front
PBIC3532J
: Engine front
PBIC3533J
Page 1703 of 2771

EM-26
< SERVICE INFORMATION >
OIL PAN
9. Insert a screwdriver shown by the arrow ( ) and open up a
crack between oil pan (upper) and cylinder block.
CAUTION:
A more adhesive liquid gasket is applied compared to previ-
ous types when shipped, so it should not be forced off the
position not specified.
10. After removing the bolts, separate the mating surface and
remove the sealant using Tool.
• Slide (1) the Tool by tapping (2) its side with a hammer to
remove the lower oil pan from the upper oil pan.
CAUTION:
Be careful not to damage the mating surfaces.
11. Remove O-ring between cylinder block and oil pan (upper).
INSPECTION AFTER REMOVAL
Oil Filter
Clean oil strainer portion (part of the oil pump) if any object attached.
INSTALLATION
1. Use a scraper (A) to remove old liquid gasket from mating sur-
faces.
• Remove the old liquid gasket from mating surface of cylinder
block.
• Remove old liquid gasket from the bolt holes and threads.
CAUTION:
Never scratch or damage the mating surfaces when clean-
ing off old liquid gasket.
: Engine front
PBIC3534J
Tool number : KV10111100 (J-37228)
WBIA0566E
PBIC3949E
Page 1704 of 2771

OIL PAN
EM-27
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2. Apply the sealant without breaks to the specified location using
Tool.
Use Genuine Silicone RTV Sealant or equivalent. Refer to
GI-42, "
Recommended Chemical Product and Sealant".
CAUTION:
Apply liquid gasket to outside of bolt hole for the positions
shown by marks.
3. Install new O-ring at cylinder block side.
CAUTION:
Install avoiding misalignment of O-ring.
4. Tighten bolts in numerical order as shown.
5. Install rear oil seal with the following procedure.
CAUTION:
• The installation of rear oil seal should be completed within 5 minutes after installing oil pan
(upper).
• Always replace rear oil seal with new one.
• Never touch oil seal lip.
a. Wipe off liquid gasket protruding to the rear oil seal mating part of oil pan (upper) and cylinder block using
a scraper.
b. Apply engine oil to entire outside area of rear oil seal.Tool number WS39930000 ( – )
1 : Oil pan (upper)
A : 2 mm protruded to outside
B : 2 mm protruded to rear oil seal mounting side
: Engine front
: Engine outside
PBIC4587E
: Engine front
PBIC3533J