Mitsubishi EVO X Operating instructions

15-1

GROUP 15

INTAKE AND

EXHAUST

CONTENTS

GENERAL INFORMATION . . . . . . . . 15-2

SERVICE SPECIFICATION . . . . . . . . 15-2

INTAKE AND EXHAUST DIAGNOSIS 15-2

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . 15-2

TROUBLESHOOTING STRATEGY . . . . . . 15-2

SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 15-2

SYMPTOM PROCEDURES . . . . . . . . . . . . 15-3

SPECIAL TOOLS. . . . . . . . . . . . . . . . 15-4

TROUBLESHOOTING . . . . . . . . . . . . 15-4

ON-VEHICLE SERVICE. . . . . . . . . . . 15-5

MANIFOLD VACUUM CHECK . . . . . . . . . . 15-5

INTAKE CHARGE PRESSURE CHECK . . 15-5

TURBOCHARGER WASTEGATE ACTUATOR

CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6

INTAKE CHARGE PRESSURE CONTROL

SYSTEM CHECK . . . . . . . . . . . . . . . . . . . . 15-7

TURBOCHARGER WASTE GATE SOLENOID

CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-8

TURBOCHARGER BYPASS VALVE

CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-9

AIR CLEANER . . . . . . . . . . . . . . . . . . 15-10

REMOVAL AND INSTALLATION . . . . . . . . 15-10

INTAKE MANIFOLD . . . . . . . . . . . . . . 15-12

REMOVAL AND INSTALLATION . . . . . . . . 15-12

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 15-14

CHARGE AIR COOLER . . . . . . . . . . . 15-15

REMOVAL AND INSTALLATION . . . . . . . . 15-15

EXHAUST MANIFOLD AND

TURBOCHARGER . . . . . . . . . . . . . . . 15-16

REMOVAL AND INSTALLATION . . . . . . . . 15-16

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 15-23

EXHAUST PIPE AND MAIN

MUFFLER . . . . . . . . . . . . . . . . . . . . . . 15-24

REMOVAL AND INSTALLATION . . . . . . . . 15-24

GENERAL INFORMATION

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INTAKE AND EXHAUST

15-2

GENERAL INFORMATION

M1151000101041

The exhaust pipe is divided into three parts.

SERVICE SPECIFICATION

M1151000301335

ITEM STANDARD VALUE LIMIT

Manifold distortion of the installation surface mm (in) 0.15 (0.006) or less 0.20 (0.008)

Intake charge pressure kPa (psi) 85 −159 (12.4 −23.0) −

Turbocharger waste gate actuator pressure kPa (psi) 98 −102 (14.3 −14.7) −

No. 1 Turbocharger waste gate solenoid terminal

resistance [at 20°C (68°F) ] Ω

29 −35 −

No. 2 Turbocharger waste gate solenoid terminal

resistance [at 20°C (68°F) ] Ω

29 −35 −

Exhaust manifold distortion of the installation surface

mm (in)

−0.70 (0.028)

INTAKE AND EXHAUST DIAGNOSIS

INTRODUCTION M1151006900406

Intake leaks usually create driveability issues that

are not obviously related to the intake system.

Exhaust leaks or abnormal noise is caused by

cracks, gaskets and fittings, or by exhaust pipe or

muffler damage due to impacts during travel. The

exhaust leaks from these sections and causes the

exhaust noise to increase. There may be cases

when the system contacts the body and vibration

noise is generated.

TROUBLESHOOTING STRATEGY M1151007000398

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 system fault.

1. Gather information from the customer.

2. Verify that the condition described by the

customer exists.

3. Find the malfunction by following the Symptom

Chart.

4. Verify malfunction is eliminated.

SYMPTOM CHART M1151007100395

Symptom Inspection procedure Reference page

Exhaust Leakage 1P.15-3

Abnormal Noise 2P.15-3

INTAKE AND EXHAUST DIAGNOSIS

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INTAKE AND EXHAUST 15-3

SYMPTOM PROCEDURES

Inspection Procedure 1: Exhaust Leakage

DIAGNOSIS

STEP 1. Start the engine. Have an assistant stay

in the driver’s seat. Raise the vehicle on a hoist.

Have the assistant rev the engine while

searching for exhaust leaks.

Q: Is the exhaust leaking?

YES : Go to Step 2.

NO : The procedure is complete.

STEP 2. Check the gasket for cracks, damage.

Q: Is the gasket damaged?

YES : Replace the gasket, then go to Step 1.

NO : Go to Step 3.

STEP 3. Check for loosening in each coupling

section.

Q: Is there any loosening in any section?

YES : Tighten, then go to Step 1.

NO : There is no action to be taken.

Inspection Procedure 2: Abnormal Noise

DIAGNOSIS

STEP 1. Start the engine. Have an assistant stay

in the drivers seat. Raise the vehicle on a hoist.

Have the assistant rev the engine while

searching for exhaust leaks.

Q: Is any abnormal noise generated?

YES : Go to Step 2.

NO : The procedure is complete.

STEP 2. 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 1.

NO : Go to Step 3.

STEP 3. Check the hanger for cracks.

Q: Is the hanger cracked?

YES : Replace, then go to Step 1.

NO : Go to Step 4.

STEP 4. 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 1.

NO : Go to Step 5.

STEP 5. Check the heat protectors.

Q: Are any heat protectors loose or damaged?

YES : Tighten or replace, then go to Step 1.

NO : Go to Step 6.

STEP 6. Check the pipes and muffler for damage.

Q: Are the pipes and muffler damaged?

YES : Replace, then go to Step 1.

NO : There is no action to be taken.

SPECIAL TOOLS

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INTAKE AND EXHAUST

15-4

SPECIAL TOOLS

M1151000601024

Tool Tool number and name Supersession Application

B992274

MB992274

Palm socket

-Removal and installation

of turbocharger

compressor bracket

MB991614

Angle gauge

General service tool Installation of

turbocharger assembly

coupling bolt and nut

B991953

MB991953

Oxygen sensor wrench

MB991953-01 Removal and installation

of heated oxygen sensor

MB992188

Fuel injection pipe

wrench

MB992188-01 Removal and installation

of No.2 air temperature

sensor

TROUBLESHOOTING

M1151010200035

Symptom Probable cause Remedy

Exhaust gas leakage Loose joints Retighten

Broken pipe or muffler Repair or replace

Abnormal noise Broken baffle in muffler Replace

Broken rubber hangers Replace

Interference of pipe or muffler with vehicle

body

Correct

Broken pipe or muffler Repair or replace

ON-VEHICLE SERVICE

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INTAKE AND EXHAUST 15-5

ON-VEHICLE SERVICE

MANIFOLD VACUUM CHECK M1151001800352

Refer to GROUP 11A, Engine Mechanical −On-vehicle Service

−Manifold Vacuum Check. P.11A-16

INTAKE CHARGE PRESSURE CHECK M1151001000549

AK703282

Cap

No. 1 turbocharger

wastegate solenoid

1. Removing the black hose from the No.1 turbocharger

wastegate solenoid or the brown connector, install the

pressure gauge to this hose. Cap the nipple of solenoid after

removing the black hose.

AK703283 AC

No. 2 turbochager

wastegate solenoid

2. Disconnect the black connector of No.2 turbocharger

wastegate solenoid.

3. When the engine speed reaches approximately 3000r/min

or more with the throttle fully opened in the second gear,

measure the boost pressure.

Standard value: 85 −159kPa (12.4 −23.0 psi)

4. If the boost pressure is lower than the standard, check the

following possible causes.

a. Turbocharger wastegate actuator malfunction

b. Boost pressure leakage

c. Turbocharger malfunction

5. If the boost pressure is higher than the standard, check on

the following areas because the boost pressure control

might be abnormal.

a. Turbocharger wastegate actuator malfunction

b. Wastegate regulating valve malfunction

c. Rubber hose of turbocharger wastegate actuator discon-

nected or cracked

AK703283 AC

No. 2 turbochager

wastegate solenoid

6. Connect the black connector of No.2 turbocharger

wastegate solenoid.

AC608435

Data link connector

MB991827

MB991824

MB991910

ON-VEHICLE SERVICE

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INTAKE AND EXHAUST

15-6

7. If the diagnostic trouble code is stored during the check, use

scan tool MB991958 to eliminate the diagnosis code.

TURBOCHARGER WASTEGATE ACTUATOR

CHECK M1151001200413

AK703279AC

Turbochager wastegate actuator

1. Connect a hand vacuum pump (pressure-application type)

to nipple.

CAUTION

In order to abovid damage to the diaphragm, do not apply

a pressure of 117 kPa (17 psi) or higher.

2. While gradually applying pressure, check the pressure that

begins to activate (approximately 1 mm stroke) the

wastegate actuator rod.

Standard value: 98 −102 kPa (14.3 −14.7 psi)

3. If there is a significant deviation from the standard value,

check the actuator or the wastegate valve: replace if

necessary.

ON-VEHICLE SERVICE

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INTAKE AND EXHAUST 15-7

INTAKE CHARGE PRESSURE CONTROL SYSTEM

CHECK M1151001100342

AK703284

Three-way joint

1. Removing the black hose from the No.1 turbocharger

wastegate solenoid or the brown connector, connect

three-way joint between the hose and the solenoid.

2. Connect the pressurized type hand vacuum pump with the

three-way joint.

AK703105

Boost hose

Turbochager

wastegate actuator

3. Use the turbocharger wastegate actuator control boost

nipple of air outlet fitting to remove the boost hose. Plug this

nipple.

CAUTION

Do not apply the pressure of 117kPA or more to prevent

the diaphragm damage.

4. Blocking or releasing the boost hose end, apply the

pressure. Check the pressurized state.

Engine state Boost hose end Normal state

Stopped: Ignition

switch in "ON"

position

Opened Pressure leaks

Closed Pressure

maintained

Rapid racing Pressure leaks

5. Put the ignition switch in "LOCK" (OFF) position.

AK703285AC

No. 1 turbochager

wastegate solenoid valve

6. Disconnect the connector of No.1 turbocharger wastegate

solenoid or the brown connector.

7. Blocking or releasing the boost hose end, apply the

pressure. Check the pressurized state. Plug the boost hose

end while driving.

Engine state Boost hose end Normal state

Stopped: Ignition

switch in "ON"

position

Opened Pressure leaks

Closed Pressure

maintained

4000r/min after

warming up

engine

Pressure leaks

NOTE: Unless the pressurized state is normal, the turbo-

charger wastegate actuator, turbocharger wastegate solenoid

or the hose might have a malfunction.

ON-VEHICLE SERVICE

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INTAKE AND EXHAUST

15-8

TURBOCHARGER WASTE GATE SOLENOID

CHECK M1151001300272

No.1 turbocharger wastegate solenoid or brown

connector

A Operation check

AK703285AC

No. 1 turbochager

wastegate solenoid valve

AK200441

BATTERY

1. Install the hand vacuum pump to the nipple "A" of solenoid.

2. Use the jumper wire to connect the solenoid terminal with

the battery terminal.

3. Disconnecting the jumper wire at the negative (-) battery

side, apply the vacuum pressure. Check the airtightness.

Jumper wire Nipple "B" state Normal state

Connected Opened Negative

pressure leaks

Closed Negative

pressure

maintained

Disconnected Opened Negative

pressure

maintained

B Check of coil resistance

AK200442

1. Measure the resistance between the solenoid terminals.

Standard value: 29 −35 Ωat 20°C

ON-VEHICLE SERVICE

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INTAKE AND EXHAUST 15-9

NO.2 turbocharger wastegate solenoid or black

connector

A Operation check

AK703283 AC

No. 2 turbochager

wastegate solenoid

AK200441

BATTERY

1. Install the hand vacuum pump to the nipple "A" of solenoid.

2. Use the jumper wire to connect the solenoid terminal with

the battery terminal.

3. Disconnecting the jumper wire at the negative (-) battery

side, apply the vacuum pressure. Check the airtightness.

Jumper wire Nipple "B" state Normal state

Connected Opened Negative

pressure leaks

Closed Negative

pressure

maintained

Disconnected Opened Negative

pressure

maintained

B Check of coil resistance

AK200442

1. Measure the resistance between the solenoid terminals.

Standard value: 29 −35 Ωat 20°C

TURBOCHARGER BYPASS VALVE CHECK

M1151001600217

AK703106AD

1. Remove the turbocharger bypass valve.

2. Connect the hand vacuum pump to the nipple of the

turbocharger bypass valve.

3. Apply a negative pressure of approximately 65 kPa (19

in.Hg) and check operation of the valve. Also check that air

tightness is maintained.

Negative pressure Valve operation

Approximately 65 kPa (19

in.Hg)

Starts opening

AIR CLEANER

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INTAKE AND EXHAUST

15-10

AIR CLEANER

REMOVAL AND INSTALLATION M1151002101951

AC710665

9.5 ± 3.5 N·m

84 ± 31 in-lb

9.5 ± 3.5 N·m

84 ± 31 in-lb

7.0 ± 3.0 N·m

62 ± 27 in-lb

4.0 ± 1.0 N·m

36 ± 8 in-lb

4.0 ± 1.0 N·m

36 ± 8 in-lb

1.5 ± 0.3 N·m

14 ± 2 in-lb

6.0 ± 1.0 N·m

53 ± 9 in-lb

8.5 ± 2.5 N·m

75 ± 22 in-lb

8.5 ± 2.5 N·m

75 ± 22 in-lb

Removal steps

1. Air cleaner intake duct

2. Air cleaner element

3. Air cleaner body

4. Air by-pass valve vacuum hose

connection

5. Air by-pass valve connection

6. Harness clamp connection

7. Mass airflow sensor connector

connection

8. Air cleaner cover assembly

<< 9. Mass airflow sensor

10. Air cleaner support

11. Gasket

12. Air cleaner cover

13. Breather hose connection

14. Vacuum hose connection

15. Air cleaner intake hose

16. Harness clamp connection

17. Air cleaner bracket

Removal steps (Continued)

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