INTAKE AND EXHAUST GROUP CONTENTS GENERAL DESCRIPTION INTAKE MANIFOLD <3.0L> INTAKE AND EXHAUST DIAGNOSIS 15-2

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1 15-1 GROUP 15 ITAKE AD EXHAUST COTETS GEERAL DESCRIPTIO ITAKE AD EXHAUST DIAGOSIS 15-2 ITRODUCTIO TO ITAKE AD EXHAUST DIAGOSIS TROUBLESHOOTIG STRATEGY SYMPTOM CHART SYMPTOM PROCEDURES SPECIAL TOOL O-VEHICLE SERVICE ITAKE MAIFOLD VACUUM CHECK AIR CLEAER REMOVAL AD ISTALLATIO ITAKE MAIFOLD PLEUM REMOVAL AD ISTALLATIO ITAKE MAIFOLD <2.4L> REMOVAL AD ISTALLATIO ISPECTIO ITAKE MAIFOLD <3.0L> REMOVAL AD ISTALLATIO ISPECTIO EXHAUST MAIFOLD <2.4L> REMOVAL AD ISTALLATIO ISPECTIO EXHAUST MAIFOLD <3.0L> REMOVAL AD ISTALLATIO ISPECTIO EXHAUST PIPE, MAI MUFFLER AD CATALYTIC COVERTER <2.4L> REMOVAL AD ISTALLATIO EXHAUST PIPE, MAI MUFFLER AD CATALYTIC COVERTER <3.0L> REMOVAL AD ISTALLATIO SPECIFICATIOS FASTEER TIGHTEIG SPECIFICATIOS SERVICE SPECIFICATIO

2 ITAKE AD EXHAUST GEERAL DESCRIPTIO The exhaust pipe is divided into five <3.0L Engine> or four <2.4L Engine> parts. GEERAL DESCRIPTIO M ITAKE AD EXHAUST DIAGOSIS ITRODUCTIO TO ITAKE AD EXHAUST DIAGOSIS The occurrence of exhaust leakage or abnormal noise is caused by cracks or strain in the gasket, or by when the exhaust pipe or muffler is damaged due to impacts during travel. The exhaust leaks from these sections and causes the exhaust noise to increase. There may be cases when there is interference with the body and vibration noise is generated. TROUBLESHOOTIG STRATEGY Use these steps to plan your diagnostic strategy. If you follow them carefully, you will be sure that you have exhausted most of the possible ways to find an intake or exhaust fault. 1. Gather information from the customer. SYMPTOM CHART M M Verify that the condition described by the customer exists. 3. Find the malfunction by following the SYMPTOM CHART. 4. Verify malfunction is eliminated. M SYMPTOMS ISPECTIO PROCEDURE REFERECE PAGE Exhaust leakage 1 P.15-3 Abnormal noise generation 2 P.15-3

3 SYMPTOM PROCEDURES ISPECTIO PROCEDURE 1: Exhaust Leakage ITAKE AD EXHAUST 15-3 ITAKE AD EXHAUST DIAGOSIS M DIAGOSIS STEP 1. Check the gasket for cracks damage. Q: Is the gasket damaged? YES : Replace the gasket, then go Step 3. O : Go to Step 2. STEP 2. Check for loosening in each coupling section. Q: Is there any loosening in each section? YES : Tighten, then go to Step 3. O : There is no action to be taken. STEP 3. Check symptom. Q: Is the exhaust leaking? YES : Return to Step 1. O : This diagnosis is complete. M ISPECTIO PROCEDURE 2: Abnormal oise DIAGOSIS STEP 1. Check for missing parts in the muffler. Tap the muffler lightly to check for loose baffles, etc. Q: Are there any missing parts in the muffler? YES : Replace, then go to Step 6. O : Go to Step 2. STEP 2. Check the hanger for cracks. Q: Is the hanger cracked? YES : Replace, then go to Step 6. O : Go to Step 3. STEP 3. Check for interference of the pipes and muffler with the body. Q: Are the pipes and muffler interfering with the body? YES : Repair, then go to Step 6. O : Go to Step 4. STEP 4. Check the heat protectors. Q: Are any heat protectors loose or damaged? YES : Tighten or replace, then go to Step 6. O : Go to Step 5. STEP 5. Check the pipes, catalytic converters and muffler for damage. Q: Are the pipes, catalytic converters and muffler damaged? YES : Replace, then go to Step 6. (For the removal of the catalytic converter, refer to GROUP 17 P ) O : There is no action to be taken. STEP 6. Check symptom. Q: Is any abnormal noise generated? YES : Return to Step 1. O : This diagnosis is complete.

4 15-4 TOOL TOOL UMBER AD AME MD Oxygen sensor wrench ITAKE AD EXHAUST SPECIAL TOOL SPECIAL TOOL SUPERSESSIO MD or general service tool APPLICATIO M Heated oxygen sensor removal and installation MD O-VEHICLE SERVICE ITAKE MAIFOLD VACUUM CHECK <2.4L EGIE> Refer to GROUP 11A, On-vehicle Service P.11A-9. <3.0L EGIE> Refer to GROUP 11C, On-vehicle Service P.11C-9. M

5 REMOVAL AD ISTALLATIO Pre-removal and Post-installation Operation Battery Removal and Installation (Refer to GROUP 54A, Battery P.54A-8.) ITAKE AD EXHAUST 15-5 AIR CLEAER AIR CLEAER M <2.4L EGIE> ± 1.0 m 38 ± 8 in-lb ± 1.0 m 38 ± 8 in-lb 8.8 ± 1.0 m 78 ± 9 in-lb ± 1.0 m 78 ± 9 in-lb <3.0L EGIE> ± 1.0 m 4 38 ± 8 in-lb ± 1.0 m 38 ± 8 in-lb ± 1.0 m 78 ± 9 in-lb 8.8 ± 1.0 m 78 ± 9 in-lb AC001421AB REMOVAL STEPS 1. AIR ITAKE HOSE 2. RESOATOR A 3. AIR DUCT 4. AIR FLOW SESOR ASSEMBLY 5. AIR CLEAER COVER REMOVAL STEPS (Continued) 6. AIR CLEAER ELEMET 7. AIR CLEAER BODY 8. AIR CLEAER BRACKET 9. RESOATOR B <2.4L EGIE> 10. RESOATOR C <3.0L EGIE>

6 15-6 ITAKE AD EXHAUST ITAKE MAIFOLD PLEUM ITAKE MAIFOLD PLEUM REMOVAL AD ISTALLATIO Pre-removal Operation Fuel Discharge Prevention [Refer to GROUP 13B, Onvehicle Service P.13B-556.] Engine Coolant Draining [Refer to GROUP 00, Maintenance Service Engine Coolant (Change) P ] Air Cleaner Removal (Refer to P.15-5.) Throttle Body Removal (Refer to GROUP 13B, Throttle Body P.13B-563.) Strut Tower Bar Removal (Refer to GROUP 42, Strut Tower Bar P ) M Post-installation Operation Throttle Body Installation (Refer to GROUP 13B, Throttle Body P.13B-563.) Air Cleaner Installation (Refer to P.15-5.) Engine Coolant Supplying [Refer to GROUP 00, Maintenance Service Engine Coolant (Change) P ] Strut Tower Bar Installation (Refer to GROUP 42, Strut Tower Bar P ) 11 ± 1 m 98 ± 8 in-lb ± 1 m 98 ± 8 in-lb ± 1.0 m 44 ± 8 in-lb ± 1.0 m 44 ± 8 in-lb 8.8 ± 1.0 m 78 ± 9 in-lb ± 1.0 m 78 ± 9 in-lb ± 1 m 98 ± 8 in-lb 8 AC AB REMOVAL STEPS 1. MAIFOLD DIFFERETIAL PRESSURE SESOR COECTOR 2. COTROL WIRIG HARESS AD POWER STEERIG WIRIG HARESS COMBIATIO COECTOR 3. EGR SOLEOID VALVE COECTOR 4. EVAPORATIVE EMISSIO PURGE SOLEOID VALVE COECTOR 5. KOCK SESOR COECTOR 6. CRAKSHAFT POSITIO SESOR COECTOR 7. RIGHT BAK HEATED OXYGE SESOR COECTOR REMOVAL STEPS (Continued) 8. IJECTOR COECTOR 9. DISTRIBUTOR COECTOR 10. COTROL WIRIG HARESS AD IJECTOR WIRIG HARESS COMBIATIO COECTOR 11. VACUUM HOSE COECTIO 12. VACUUM PIPE 13. EGR SOLEOID VALVE, EVAPORATIVE EMISSIO PURGE SOLEOID VALVE AD VACUUM COTROL VALVE 14. BRAKE BOOSTER VACUUM HOSE COECTIO

7 ITAKE AD EXHAUST 15-7 ITAKE MAIFOLD PLEUM 21 ± 4 m 16 ± 3 ft-lb ± 2 m 13 ± 1 ft-lb ± 2 m 13 ± 1 ft-lb 18 ± 2 m 13 ± 1 ft-lb 35 ± 6 m 26 ± 4 ft-lb 44 ± 10 m 33 ± 7 ft-lb ± 6 m 26 ± 4 ft-lb ± 1.0 m 44 ± 8 in-lb 18 ± 2 m 13 ± 1 ft-lb 42 ± 7 m 31 ± 5 ft-lb ± 4 m 17 ± 3 ft-lb 34 ± 5 m 26 ± 3 ft-lb 18 ± 2 m 13 ± 1 ft-lb ± 2 m 13 ± 1 ft-lb REMOVAL STEPS 15. EGR VALVE 16. EGR PIPE COECTIO 17. DRIVE BELT <POWER STEERIG OIL PUMP> 18. POWER STEERIG OIL PUMP BRACKET STAY 19. ITAKE MAIFOLD PLEUM STAY, FROT >>A<< AC001423AB REMOVAL STEPS (Continued) 20. ITAKE MAIFOLD PLEUM STAY, REAR 21. EGIE MOUT STAY 22. ITAKE MAIFOLD PLEUM 23. ITAKE MAIFOLD PLEUM GASKET 24. MAIFOLD DIFFERETIAL PRESSURE SESOR

8 15-8 ITAKE AD EXHAUST ITAKE MAIFOLD <2.4L> ISTALLATIO SERVICE POIT >>A<< ITAKE MAIFOLD PLEUM GASKET ISTALLATIO Install the gasket with the protrusion in the position illustrated. PROTRUSIO FROT OF VEHICLE AC001424AB ITAKE MAIFOLD <2.4L> REMOVAL AD ISTALLATIO Pre-removal Operation Fuel Discharge Prevention [Refer to GROUP 13A, Onvehicle Service Fuel Pump Relay Disconnection (How to Reduce Pressurized Fuel Lines).] Engine Coolant Draining [Refer to GROUP 00, Maintenance Service Engine Coolant (Change) P ] Air Cleaner Removal (Refer to P.15-5.) Throttle Body Removal (Refer to GROUP 13A, Throttle Body P.13A-488.) Thermostat Case Assembly Removal (Refer to GROUP 14, Water Hose and Water Pipe P ) M Post-installation Operation Thermostat Case Assembly Installation (Refer to GROUP 14, Water Hose and Water Pipe P ) Throttle Body Installation (Refer to GROUP 13A, Throttle Body P.13A-488.) Air Cleaner Installation (Refer to P.15-5.) Engine Coolant Supplying [Refer to GROUP 00, Maintenance Service Engine Coolant (Change) P ] Fuel Leakage Inspection

9 ITAKE AD EXHAUST 15-9 ITAKE MAIFOLD <2.4L> ± 1.0 m 44 ± 8 in-lb ± 1 m 117 ± 13 in-lb 11 REMOVAL STEPS 1. PURGE HOSE COECTIO 2. BRAKE BOOSTER VACUUM HOSE COECTIO 3. IGITIO COIL COECTOR 4. IJECTOR COECTOR 5. IGITIO FAILURE SESOR COECTOR 6. MAIFOLD DIFFERETIAL PRESSURE SESOR COECTOR 7. EVAPORATIVE EMISSIO PURGE SOLEOID VALVE COECTOR ± 2 m 100 ± 22 in-lb (EGIE OIL) >>A<< 9 O-RIG EGIE OIL FUEL RAIL AC004224AC REMOVAL STEPS (Continued) 8. EGR SOLEOID VALVE COECTOR 9. HIGH-PRESSURE FUEL HOSE COECTIO 10. FUEL RETUR HOSE COECTIO 11. OIL DIPSTICK AD DIPSTICK GUIDE 12. PRESSURE HOSE COECTIO

10 15-10 ITAKE AD EXHAUST ITAKE MAIFOLD <2.4L> 11 ± 1 m 98 ± 8 in-lb ± 2 m 14 ± 2 ft-lb 4.9 ± 1.0 m 44 ± 8 in-lb 11 ± 1 m 98 ± 8 in-lb ± 1.0 m 44 ± 8 in-lb ± 1.0 m 78 ± 9 in-lb ± 1 m 100 ± 13 in-lb ± 4 m 16 ± 3 ft-lb ± 2 m 14 ± 2 ft-lb ± 1.0 m 78 ± 9 in-lb 30 ± 3 m 23 ± 2 ft-lb <<A>> REMOVAL STEPS 13. PCV HOSE 14. FUEL RETUR PIPE 15. FUEL HOSE 16. FUEL RAIL, IJECTOR AD FUEL PRESSURE REGULATOR 17. ISULATOR 18. VACUUM PIPE 19. EGR VALVE 20. ITAKE MAIFOLD 21. ITAKE MAIFOLD GASKET 8.9 ± 1.9 m 78 ± 17 in-lb AC001430AC REMOVAL STEPS (Continued) 22. ITAKE MAIFOLD STAY 23. IGITIO FAILURE SESOR 24. MAIFOLD DIFFERETIAL PRESSURE SESOR 25. VACUUM PIPE 26. EVAPORATIVE EMISSIO PURGE SOLEOID VALVE 27. EGR SOLEOID VALVE AD VACUUM COTROL VALVE 28. ACCELERATOR CABLE CLAMP REMOVAL SERVICE POIT <<A>> FUEL RAIL, IJECTOR AD FUEL PRESSURE REGULATOR REMOVAL CAUTIO Care must be taken when removing the fuel rail not to drop the injector. Remove the fuel rail with the injectors and pressure regulator attached to it.

11 HIGH-PRESSURE FUEL HOSE O-RIG FUEL RAIL AC001431AB ITAKE AD EXHAUST ITAKE MAIFOLD <2.4L> ISTALLATIO SERVICE POIT >>A<< HIGH-PRESSURE FUEL HOSE ISTALLATIO CAUTIO Be careful not to allow any engine oil to enter the fuel rail. 1. When connecting the high-pressure fuel hose to the fuel rail, apply a small amount of new engine oil to the O-ring and then insert the high-pressure fuel hose, being careful not to damage the O-ring. 2. While turning the high-pressure fuel hose to the left and right, install it to the fuel rail. 3. Check that the injector turns smoothly. If it does not turn smoothly, the O-ring may be trapped. Remove the highpressure fuel hose and then re-insert it into the fuel rail and check again. ISPECTIO M Check the following points; replace the part if a problem is found. ITAKE MAIFOLD CHECK 1. 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 or gas passage. 3. Using a straight edge and feeler gauge, check for distortion of the cylinder head installation surface. Standard value: 0.15 mm (0.006 inch) or less Limit: 0.20 mm (0.008 inch)

12 15-12 REMOVAL AD ISTALLATIO Pre-removal Operation Fuel Discharge Prevention [Refer to GROUP 13B, Onvehicle Service Fuel Pump Relay Disconnection (How to Reduce Pressurized Fuel Lines) P.13B-556.] Intake Manifold Plenum Removal (Refer to P.15-6.) ITAKE AD EXHAUST ITAKE MAIFOLD <3.0L> ITAKE MAIFOLD <3.0L> Post-installation Operation Intake Manifold Plenum Installation (Refer to P.15-6.) Fuel Leakage Inspection M ± 1 m 100 ± 13 in-lb ± 1.0 m 44 ± 8 in-lb ITAKE MAIFOLD MOUTIG STUD CYLIDER HEAD 23 ± 3 m 17 ± 3 ft-lb 8 22 ± 1 m 16 ± 1 ft-lb ± 1 m 16 ± 1 ft-lb EGIE OIL ± 1 m 98 ± 8 in-lb 14 ± 1 m 117 ± 13 in-lb 10 AC001432AB >>C<< REMOVAL STEPS 1. IJECTOR COECTOR 2. HIGH-PRESSURE FUEL HOSE COECTIO 3. O-RIG 4. FUEL RETUR HOSE COECTIO 5. VACUUM HOSE COECTIO <<A>> REMOVAL STEPS (Continued) 6. FUEL RAIL, IJECTOR AD FUEL PRESSURE REGULATOR 7. ISULATORS 8. ISULATORS 9. PCV HOSE COECTIO 10. TIMIG BELT FROT UPPER COVER, RIGHT 11. BRACKET

13 ITAKE AD EXHAUST ITAKE MAIFOLD <3.0L> >>B<< >>A<< REMOVAL STEPS (Continued) 12. ITAKE MAIFOLD 13. ITAKE MAIFOLD GASKET PROTRUSIO FROT OF VEHICLE REMOVAL SERVICE POIT <<A>> FUEL RAIL, IJECTOR AD FUEL PRESSURE REGULATOR REMOVAL CAUTIO Care must be taken when removing the fuel rail not to drop the injector. Remove the fuel rail with the injectors and pressure regulator attached to it. ISTALLATIO SERVICE POITS >>A<< ITAKE MAIFOLD GASKET ISTALLATIO Install the gasket with the protrusions in the position illustrated. PROTRUSIO ACX02434AC RIGHT BAK LEFT BAK AC001433AB >>B<< ITAKE MAIFOLD ISTALLATIO 1. Coat the intake manifold mounting studs with engine oil. 2. Tighten the intake manifold mounting nuts by the following procedure. ORDER MOUTIG UTS TIGHTEIG TORQUE 1st Right-bank nuts 6.4 ± 1.4 m (56 ± 13 in-lb) 2nd Left-bank nuts 22 ± 1 m (16 ± 1 ft-lb) 3rd Right-bank nuts 22 ± 1 m (16 ± 1 ft-lb) 4th Left-bank nuts 22 ± 1 m (16 ± 1 ft-lb) 5th Right-bank nuts 22 ± 1 m (16 ± 1 ft-lb)

14 15-14 FUEL RAIL O-RIG HIGH- PRESSURE FUEL HOSE AC001436AB ITAKE AD EXHAUST ITAKE MAIFOLD <3.0L> >>C<< HIGH-PRESSURE FUEL HOSE ISTALLATIO CAUTIO Be careful not to allow any engine oil to enter the fuel rail. 1. When connecting the high-pressure fuel hose to the fuel rail, apply a small amount of new engine oil to the O-ring and then insert the high-pressure fuel hose, being careful not to damage the O-ring. 2. While turning the high-pressure fuel hose to the left and right, install it to the fuel rail. 3. Check that the injector turns smoothly. If it does not turn smoothly, the O-ring may be trapped. Remove the highpressure fuel hose and then re-insert it into the fuel rail and check again. ISPECTIO M Check the following points; replace the part if a problem is found. ITAKE MAIFOLD CHECK 1. 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 or gas passage. 3. Using a straight edge and feeler gauge, check for distortion of the cylinder head installation surface. Standard value: 0.15 mm (0.006 inch) or less Limit: 0.20 mm (0.008 inch)

15 REMOVAL AD ISTALLATIO ITAKE AD EXHAUST EXHAUST MAIFOLD <2.4L> EXHAUST MAIFOLD <2.4L> M ± 5 m 36 ± 4 ft-lb 29 ± 3 m 22 ± 2 ft-lb 14 ± 1 m 120 ± 13 in-lb ± 1 m 120 ± 13 in-lb 49 ± 5 m 36 ± 4 ft-lb ± 3 m 22 ± 2 ft-lb 44 ± 5 m 33 ± 3 ft-lb <<A>> >>A<< 35 ± 6 m 26 ± 4 ft-lb 49 ± 10 m 37 ± 7 ft-lb REMOVAL STEPS 1. HEATED OXYGE SESOR (FROT) 2. HEAT PROTECTOR 3. EGIE HAGER AC001808AD REMOVAL STEPS (Continued) 4. EXHAUST MAIFOLD 5. EXHAUST MAIFOLD GASKET 6. GASKET 7. EXHAUST MAIFOLD BRACKET

16 15-16 ITAKE AD EXHAUST EXHAUST MAIFOLD <2.4L> REMOVAL SERVICE POIT <<A>> HEATED OXYGE SESOR (FROT) REMOVAL Use special tool MD to remove the oxygen sensor. MD ACX02426AB ISTALLATIO SERVICE POIT >>A<< HEATED OXYGE SESOR (FROT) ISTALLATIO Use special tool MD to installation the oxygen sensor. MD ACX02426AB ISPECTIO M Check the following points; replace the part if a problem is found. EXHAUST MAIFOLD 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 (0.006 inch) or less Limit: 0.20 mm (0.008 inch)

17 REMOVAL AD ISTALLATIO ITAKE AD EXHAUST EXHAUST MAIFOLD <3.0L> EXHAUST MAIFOLD <3.0L> Pre-removal and Post-installation Operation Front Exhaust Pipe Removal and Installation (Refer to P ) Air Cleaner Removal and Installation (Refer to P.15-5.) Battery and Battery Tray Removal and Installation (Refer to GROUP 54A, Battery P.54A-8.) Engine Oil Dipstick Guide, A/T Oil Dipstick Guide Removal and Installation Strut Tower Bar Removal and Installation (Refer to GROUP 42, Strut Tower Bar P ) 14 ± 1 m 120 ± 13 in-lb 18 ± 2 m 13 ± 1 ft-lb 8 14 ± 1 m 120 ± 13 in-lb M ± 10 m 44 ± 7 ft-lb 44 ± 5 m 33 ± 3 ft-lb 2 14 ± 1 m 120 ± 13 in-lb 9 14 ± 1 m 120 ± 13 in-lb ± 5 m 33 ± 3 ft-lb ± 1 m 120 ± 13 in-lb 5 <<A>> >>A<< REMOVAL STEPS 1. HEAT UPPER PROTECTOR <LEFT BAK> 2. LEFT BAK HEATED OXYGE SESOR (FROT) 3. HEAT PROTECTOR <LEFT BAK> 4. HEAT LOWER PROTECTOR <LEFT BAK> 5. EXHAUST MAIFOLD <LEFT BAK> 6. EXHAUST MAIFOLD GASKET <LEFT BAK> 7. EGR PIPE 14 ± 1 m 120 ± 13 in-lb 4 44 ± 5 m 33 ± 3 ft-lb AC004226AC REMOVAL STEPS (Continued) 8. HEAT UPPER PROTECTOR <RIGHT BAK> 9. HEAT PROTECTOR <RIGHT BAK> 10. HEAT FROT PROTECTOR <RIGHT BAK> 11. HEAT LOWER PROTECTOR <RIGHT BAK> 12. EXHAUST MAIFOLD <RIGHT BAK> 13. EXHAUST MAIFOLD GASKET <RIGHT BAK>

18 15-18 ITAKE AD EXHAUST EXHAUST MAIFOLD <3.0L> REMOVAL SERVICE POIT <<A>> LEFT BAK HEATED OXYGE SESOR (FROT) REMOVAL Use special tool MD to remove the oxygen sensor. MD ACX02426AB ISTALLATIO SERVICE POIT >>A<< LEFT BAK HEATED OXYGE SESOR (FROT) ISTALLATIO Use special tool MD to installation the oxygen sensor. MD ACX02426AB ISPECTIO M Check the following points; replace the part if a problem is found. EXHAUST MAIFOLD 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 (0.006 inch) or less Limit: 0.20 mm (0.008 inch)

19 ITAKE AD EXHAUST EXHAUST PIPE, MAI MUFFLER AD CATALYTIC COVERTER <2.4L> EXHAUST PIPE, MAI MUFFLER AD CATALYTIC COVERTER <2.4L> REMOVAL AD ISTALLATIO M ± 2 m 3 12 ± 2 m 2 12 ± 2 m 49 ± 10 m 37 ± 7 ft-lb ± 5 m 33 ± 3 ft-lb ± 2 m 8 49 ± 10 m 37 ± 7 ft-lb MAI MUFFLER REMOVAL STEPS 1. MAI MUFFLER 2. HAGER 3. HAGER CETER EXHAUST PIPE REMOVAL STEPS 4. CETER EXHAUST PIPE 5. HAGER 6. HAGER 7. PROTECTOR 4 <<A>> 7 6 >>A<< 12 ± 2 m ± 4 m 26 ± 3 ft-lb 12 ± 2 m AC004227AC FROT EXHAUST PIPE REMOVAL STEPS 8. HEATED OXYGE SESOR (REAR) 9. FROT EXHAUST PIPE (CATALYTIC COVERTER ICORPORATED) 10. HAGER REMOVAL SERVICE POIT <<A>> HEATED OXYGE SESOR (REAR) REMOVAL Use special tool MD to remove the oxygen sensor. MD ACX02426AB

20 15-20 ITAKE AD EXHAUST EXHAUST PIPE, MAI MUFFLER AD CATALYTIC COVERTER <2.4L> ISTALLATIO SERVICE POIT >>A<< HEATED OXYGE SESOR (REAR) ISTALLATIO Use special tool MD to install the oxygen sensor. MD ACX02426AB

21 ITAKE AD EXHAUST EXHAUST PIPE, MAI MUFFLER AD CATALYTIC COVERTER <3.0L> EXHAUST PIPE, MAI MUFFLER AD CATALYTIC COVERTER <3.0L> REMOVAL AD ISTALLATIO ± 5 m 33 ± 3 ft-lb 35 ± 4 m 26 ± 3 ft-lb 32 ± 7 m 24 ± 5 ft-lb 12 ± 2 m 49 ± 9 m 37 ± 6 ft-lb <<A>> ± 5 m 33 ± 3 ft-lb 35 ± 4 m 26 ± 3 ft-lb ± 5 m 33 ± 3 ft-lb 12 ± 2 m >>A<< ± 9 m 37 ± 6 ft-lb MAI MUFFLER REMOVAL STEPS 1. MAI MUFFLER 2. HAGER 3. HAGER CETER EXHAUST PIPE REMOVAL STEPS 4. CETER EXHAUST PIPE 5. HAGER 6. HAGER 7. PROTECTOR FROT EXHAUST PIPE REMOVAL STEPS (LEFT BAK SIDE) 8. HAGER 9. LEFT BAK HEATED OXYGE SESOR (REAR) 10. EXHAUST FITTIG STAY (LH) 32 ± 7 m 24 ± 5 ft-lb 12 ± 2 m 49 ± 9 m 37 ± 6 ft-lb 4 <<A>> <<A>> 7 12 ± 2 m 6 >>A<< >>A<< 12 ± 2 m 3 12 ± 2 m 5 35 ± 4 m 26 ± 3 ft-lb M ± 2 m AC004228AC FROT EXHAUST PIPE REMOVAL STEPS (LEFT BAK SIDE) (Continued) 11. FROT CATALYTIC COVERTER (LH) FROT EXHAUST PIPE REMOVAL STEPS (RIGHT BAK SIDE) 12. RIGHT BAK HEATED OXYGE SESOR (FROT) 13. RIGHT BAK HEATED OXYGE SESOR (REAR) 14. EXHAUST FITTIG STAY (RH) 15. FROT CATALYTIC COVERTER (RH) 16. FROT EXHAUST PIPE (CATALYTIC COVERTER ICORPORATED)

22 15-22 ITAKE AD EXHAUST SPECIFICATIOS REMOVAL SERVICE POIT <<A>> LEFT BAK HEATED OXYGE SESOR (REAR)/ RIGHT BAK HEATED OXYGE SESOR (REAR)/RIGHT BAK HEATED OXYGE SESOR (FROT) REMOVAL Use special tool MD to remove the oxygen sensor. MD ACX02426AB ISTALLATIO SERVICE POIT >>A<<RIGHT BAK HEATED OXYGE SESOR (FROT)/ RIGHT BAK HEATED OXYGE SESOR (REAR)/LEFT BAK HEATED OXYGE SESOR (REAR) ISTALLATIO Use special tool MD to install the oxygen sensor. MD ACX02426AB SPECIFICATIOS FASTEER TIGHTEIG SPECIFICATIOS ITEMS Air cleaner Air cleaner bolt Air flow sensor nut Air intake hose clamp bolt Exhaust manifold <2.4L Engine> Engine hanger nut Exhaust manifold bracket bolt Exhaust manifold nut Front exhaust pipe nut M SPECIFICATIOS 8.8 ± 1.0 m (78 ± 9 in-lb) 8.8 ± 1.0 m (78 ± 9 in-lb) 3.9 ± 1.0 m (38 ± 8 in-lb) 29 ± 3 m (22 ± 2 ft-lb) 35 ± 6 m (26 ± 4 ft-lb) M829 ± 3 m (22 ± 2 ft-lb) M10 49 ± 5 m (36 ± 4 ft-lb) 49 ± 10 m (37 ± 7 ft-lb)

23 ITAKE AD EXHAUST SPECIFICATIOS ITEMS Heat protector bolt Heated oxygen sensor (front) Exhaust manifold <3.0L Engine> EGR pipe bolt EGR pipe gasket bolt Exhaust manifold nut Heat front protector <right bank> bolt Heat lower protector <left bank> bolt Heat lower protector <right bank> bolt Heat protector <left bank> bolt Heat protector <right bank> bolt Heat upper protector <left bank> bolt Heat upper protector <right bank> bolt Left bank heated oxygen sensor (front) Exhaust pipe and main muffler <2.4L Engine> Center exhaust pipe bolt Front exhaust pipe nut Hanger bolt Heated oxygen sensor (rear) Exhaust pipe and main muffler <3.0L Engine> Center exhaust pipe bolt Exhaust fitting stay (LH) Exhaust fitting stay (RH) Front catalytic converter (LH) nut Front catalytic converter (RH) nut Front exhaust pipe nut Hanger bolt Left bank heated oxygen sensor (rear) Right bank heated oxygen sensor (front) Right bank heated oxygen sensor (rear) Intake manifold <2.4L Engine> Accelerator cable clamp bolt EGR solenoid valve bolt EGR valve bolt Evaporative emission purge solenoid valve bolt Fuel rail bolt High pressure fuel hose connection bolt Intake manifold bolt and nut SPECIFICATIOS 14 ± 1 m (120 ± 13 in-lb) 44 ± 5 m (33 ± 3 ft-lb) 59 ± 10 m (44 ± 7 ft-lb) 18 ± 2 m (13 ± 2 ft-lb) 44 ± 5 m (33 ± 3 ft-lb) 14 ± 1 m (120 ± 13 in-lb) 14 ± 1 m (120 ± 13 in-lb) 14 ± 1 m (120 ± 13 in-lb) 14 ± 1 m (120 ± 13 in-lb) 14 ± 1 m (120 ± 13 in-lb) 14 ± 1 m (120 ± 13 in-lb) 14 ± 1 m (120 ± 13 in-lb) 44 ± 5 m (33 ± 3 ft-lb) 35 ± 4 m (26 ± 3 ft-lb) 49 ± 10 m (37 ± 7 ft-lb) 12 ± 2 m () 44 ± 5 m (33 ± 3 ft-lb) 35 ± 4 m (26 ± 3 ft-lb) M812 ± 2 m () M12 32 ± 7 m (24 ± 5 ft-lb) M812 ± 2 m () M12 32 ± 7 m (24 ± 5 ft-lb) 35 ± 4 m (26 ± 3 ft-lb) 35 ± 4 m (26 ± 3 ft-lb) 49 ± 9 m (37 ± 6 ft-lb) 12 ± 2 m () 44 ± 5 m (33 ± 3 ft-lb) 44 ± 5 m (33 ± 3 ft-lb) 44 ± 5 m (33 ± 3 ft-lb) 11 ± 1 m (98 ± 8 in-lb) 8.8 ± 1.0 m (78 ± 9 in-lb) 21 ± 4 m (16 ± 3 ft-lb) 8.8 ± 1.0 m (78 ± 9 in-lb) 12 ± 1 m (100 ± 13 in-lb) 4.9 ± 1.0 m (44 ± 8 in-lb) 20 ± 2 m (14 ± 2 ft-lb)

24 15-24 ITAKE AD EXHAUST SPECIFICATIOS ITEMS SPECIFICATIOS Intake manifold stay bolt 30 ± 3 m (23 ± 2 ft-lb) Manifold differential pressure sensor and ignition failure sensor bolt 4.9 ± 1.0 m (44 ± 8 in-lb) Oil dipstick guide bolt 14 ± 1 m (117 ± 13 in-lb) Vacuum pipe bolt 11 ± 1 m (98 ± 8 in-lb) Intake manifold <3.0L Engine> Bracket bolt 23 ± 3 m (17 ± 3 ft-lb) Fuel rail bolt 12 ± 1 m (100 ± 13 in-lb) High pressure fuel hose connection bolt 4.9 ± 1.0 m (44 ± 8 in-lb) Intake manifold nut 22 ± 1 m (16 ± 1 ft-lb) Timing belt front upper cover bolt M6 11 ± 1 m (98 ± 8 in-lb) M814 ± 1 m (117 ± 13 in-lb) Intake manifold plenum <3.0L Engine> Control wiring harness connector bracket bolt 4.9 ± 1.0 m (44 ± 8 in-lb) EGR pipe connection bolt 18 ± 2 m (13 ± 1 ft-lb) EGR valve bolt 21 ± 4 m (16 ± 3 ft-lb) Engine mount stay bolt 34 ± 5 m (26 ± 3 ft-lb) Heater pipe bolt 18 ± 2 m (13 ± 1 ft-lb) Intake manifold plenum bolt and nut 18 ± 2 m (13 ± 1 ft-lb) Intake manifold plenum stay bolt, front and rear M818± 2 m (13 ± 1 ft-lb) M10 35 ± 6 m (26 ± 4 ft-lb) Manifold differential pressure sensor bolt 4.9 ± 1.0 m (44 ± 8 in-lb) Power steering oil pump stay bolt (bolt, washer assembly) 44 ± 10 m (33 ± 7 ft-lb) Power steering oil pump stay bolt (bolt, flange) 23 ± 4 m (17 ± 3 ft-lb) Power steering oil pump nut 42 ± 7 m (31 ± 5 ft-lb) Sensor connector assembly bolt 11 ± 1 m (98 ± 8 in-lb) Vacuum pipe assembly bolt 11 ± 1 m (98 ± 8 in-lb) Valve assembly bolt 8.8 ± 1.0 m (78 ± 9 in-lb) SERVICE SPECIFICATIO ITEM STADARD VALUE LIMIT Manifold distortion of the installation surface mm (in) 0.15 (0.006) or less 0.20 (0.008) M

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