15sPACE WAGON

8/16/2019 15sPACE WAGON

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15-1

INTAKE ANDEXHAUSTCONTENTS 15109000250

GENERAL INFORMATION 2. . . . . . . . . . . . . . . . . .

SERVICE SPECIFICATION 2. . . . . . . . . . . . . . . . . .

SPECIAL TOOL 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

INTAKE MANIFOLD 3. . . . . . . . . . . . . . . . . . . . . . . .

EXHAUST MANIFOLD 6. . . . . . . . . . . . . . . . . . . . . .

EXHAUST PIPE AND MAIN MUFFLER 8. . . . . .

http://g-title.pdf/http://g-title.pdf/http://g-title.pdf/http://g-title.pdf/


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INTAKE AND EXHAUST - General Information/Service Specification/Special Tool15-2

GENERAL INFORMATION 15100010061The intake manifold is made of an aluminium alloy,and the shape provides an increased intake inertiaeffect and has a good volumetric efficiency.

The exhaust manifold is made of stainless steel.The exhaust pipe is divided into three parts; thefront pipe, the centre pipe, and the main muffler.

SERVICE SPECIFICATION 15100030197

Items Standard value Limit

Manifold distortion of the installation surface mm 0.15 or less 0.20

SPECIAL TOOL 15100060066

Tool Number Name Use

MD998770 Oxygen sensorwrench

Removal/Installation of oxygen sensor

http://../SUPPLEMENT/2000/15.pdfhttp://../SUPPLEMENT/2000/15.pdf


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INTAKE AND EXHAUST - Intake Manifold 15-3

INTAKE MANIFOLD 15100300441REMOVAL AND INSTALLATION

Pre-removal and Post-installation OperationD Engine Coolant Draining and Supplying

(Refer to GROUP 14 - On-vehicle Service.)D Engine Cover Removal and InstallationD Air Cleaner Assembly Removal and Installation

D Ignition Coil Removal and Installation(Refer to GROUP 16.)

D Throttle Body Removal and Installation(Refer to GROUP 13A.)

1

2

3

4

5

10 - 12 Nm

20 Nm

20 Nm

9 Nm

13

6

815

7

12

8

18

10

14

30 Nm

9 Nm

9

30 Nm

1617

11

24 Nm

Removal steps1. Engine harness connector and clamp2. Earth cable connection3. PCV hose4. Brake booster vacuum hose

connection5. Vacuum hose connection6. Purge solenoid valve7. Vacuum pipe and hose assembly8. Intake manifold and air intake plenum

resonator assembly connecting bolt9. Intake manifold stay and air intake

plenum resonator assemblyconnecting bolt

10. Intake manifold and stay connectingbolt

11. Intake manifold and EGR valvesupport connecting bolt

12. Intake manifold13. Intake manifold gasket14. Gasket15. Air intake plenum resonator assembly16. Power steering hose clamp17. Alternator harness clamp18. Intake manifold stay



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INTAKE AND EXHAUST - Intake Manifold15-4

Pre-removal and Post-installation OperationD Engine Coolant Draining and Supplying

(Refer to GROUP 14 - On-vehicle Service.)D Engine Cover Removal and InstallationD Ignition Coil Removal and Installation

(Refer to GROUP 16.)

D Air Cleaner Assembly Removal and InstallationD Throttle Body Removal and Installation

(Refer to GROUP 13B.)

6

7

810

14

19 Nm

20 Nm9 Nm

9 Nm10 - 12 Nm

9 Nm

326

9

1

3

2

16

25

24

49 Nm

2223

24 Nm

133

5

213

19 Nm

12

1919 2019 Nm

15 18

11

17

25 - 32 Nm

10 - 12 Nm25 - 32 Nm


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INTAKE AND EXHAUST - Intake Manifold 15-5

Intake manifold removal steps1. Brake booster vacuum pipe2. Brake booster vacuum hose3. Harness connector4. Vacuum hose5. Vacuum pipe and pipe6. Purge control solenoid valve7. Harness clamp8. PCV hose connection9. Water hose connectionD Front exhaust pipe assembly

(Refer to P.15-8.)10. Intake manifold and air intake plenum

resonator assembly connecting bolt11. Intake manifold and stay connecting

bolt12. Intake manifold and EGR valve

support connecting bolt13. EGR pipe gasket14. Intake manifold assembly15. Intake manifold gasket

16. Air intake plenum resonator assembly17. Harness connector clamp18. Intake manifold stayEGR valve removal steps3. Harness connector

12. Intake manifold and EGR valvesupport connecting bolt

13. EGR valve gasket19. Water hose connection20. EGR valve21. EGR valve gasket22. EGR valve support23. EGR valve gasketAir bypass valve removal steps

14. Intake manifold assembly24. Water hose connection25. Air bypass valve26. Air bypass valve gasket

INSPECTION 15100310161

Check the following points; replace the part if a problem isfound.

INTAKE MANIFOLD CHECK1. Check for damage or cracking of any part.2. Check for obstruction of the negative pressure (vacuum)

outlet port, and for obstruction of the water passage orgas passage.

3. Using a straight edge and thickness gauge, check fordistortion of the cylinder head installation surface.

Standard value: 0.15 mm or lessLimit: 0.20 mm


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INTAKE AND EXHAUST - Exhaust Manifold15-6

EXHAUST MANIFOLD 15100330440REMOVAL AND INSTALLATION

Pre-removal and Post-installation OperationUnder Cover Removal and Installation

29 Nm

2

49 Nm7

4

13 Nm

12 - 15 Nm

6

49 Nm

134 Nm

44 Nm

7 618 Nm

29 Nm

29 Nm 5

4

5

35 Nm

19 Nm

2

1

44 Nm

34 Nm

3

12 - 15 Nm

Removal steps1. Front exhaust pipe connection2. Gasket3. Oil level gauge assembly 4. Heat protector

5. Exhaust manifold bracket 6. Exhaust manifold7. Exhaust manifold gasket



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INTAKE AND EXHAUST - Exhaust Manifold 15-7

INSPECTION 15100340061EXHAUST MANIFOLD CHECK1. Check for damage or cracking of any part.2. Using a straight edge and thickness gauge, check for

distortion of the cylinder head installation surface.Standard value: 0.15 mm or lessLimit: 0.20 mm


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INTAKE AND EXHAUST - Exhaust Pipe and Main MufflerINTAKE AND EXHAUST - Exhaust Pipe and Main Muffler15-8

EXHAUST PIPE AND MAIN MUFFLER 15100540355REMOVAL AND INSTALLATION

Pre-removal and Post-installation OperationUnder Cover Removal and Installation

Hanger installationbolt tightening torque

2

5

5

6

8

1

11

12

1314

15

4 49 Nm

49 Nm

13 Nm

49 Nm

7

10

54 Nm

34 Nm

13 Nm

9

3

5, 8, 13

44 Nm

54 Nm

Main muffler removal steps1. Main muffler assembly2. Gasket3. HangerCenter exhaust pipe removal steps

A A" " AA 2. Oxygen sensor 3. Center exhaust pipe4. Gasket7. Gasket8. Hanger

Catalytic converter removal steps6. Catalytic converter7. Gasket

11. GasketFront exhaust pipe removal steps

A A" " AA 9. Oxygen sensor10. Front exhaust pipe11. Gasket12. Gasket13. Hanger14. Front hanger bracket15. Front exhaust pipe bracket

REMOVAL SERVICE POINTA A" OXYGEN SENSOR REMOVAL

INSTALLATION SERVICE POINT" AA OXYGEN SENSOR INSTALLATION

MD998770

15sPACE WAGON

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