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Mitsubishi EVO X Repair Manual

Intake and exhaust
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GENERAL INFORMATION . . . . . . . .
SERVICE SPECIFICATION . . . . . . . .
INTRODUCTION. . . . . . . . . . . . . . . . . . . . .
SYMPTOM CHART. . . . . . . . . . . . . . . . . . .
SYMPTOM PROCEDURES . . . . . . . . . . . .
SPECIAL TOOLS. . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . .
ON-VEHICLE SERVICE. . . . . . . . . . .
MANIFOLD VACUUM CHECK . . . . . . . . . .
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SYSTEM CHECK . . . . . . . . . . . . . . . . . . . .
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GROUP 15
INTAKE AND
EXHAUST
CONTENTS
15-2
15-2
15-2
15-2
15-2
15-2
15-3
15-4
15-4
15-5
15-5
15-5
15-6
15-7
15-8
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CLEANER . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
INTAKE MANIFOLD . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
CHARGE AIR COOLER . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
TURBOCHARGER . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
MUFFLER . . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
15-1
15-9
15-10
15-10
15-12
15-12
15-14
15-15
15-15
15-16
15-16
15-23
15-24
15-24

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Summary of Contents for Mitsubishi EVO X

  • Page 1: Table Of Contents

    15-1 GROUP 15 INTAKE AND EXHAUST CONTENTS GENERAL INFORMATION ..15-2 TURBOCHARGER BYPASS VALVE CHECK ......15-9 SERVICE SPECIFICATION .

  • Page 2: General Information

    15-2 INTAKE AND EXHAUST GENERAL INFORMATION 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) 85 − 159 (12.4 − 23.0) Intake charge pressure kPa (psi) −...

  • Page 3: Symptom Procedures

    15-3 INTAKE AND EXHAUST INTAKE AND EXHAUST DIAGNOSIS SYMPTOM PROCEDURES Inspection Procedure 1: Exhaust Leakage DIAGNOSIS STEP 2. Check the gasket for cracks, damage. Q: Is the gasket damaged? STEP 1. Start the engine. Have an assistant stay Replace the gasket, then go to Step 1. YES : in the driver’s seat.

  • Page 4: Special Tools

    15-4 INTAKE AND EXHAUST SPECIAL TOOLS SPECIAL TOOLS M1151000601024 Tool Tool number and name Supersession Application MB992274 Removal and installation Palm socket of turbocharger compressor bracket B992274 MB991614 General service tool Installation of Angle gauge turbocharger assembly coupling bolt and nut MB991614 MB991953 MB991953-01...

  • Page 5: On-Vehicle Service

    15-5 INTAKE AND EXHAUST ON-VEHICLE SERVICE 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 1. Removing the black hose from the No.1 turbocharger wastegate solenoid or the brown connector, install the No.

  • Page 6: Turbocharger Wastegate Actuator Check

    15-6 INTAKE AND EXHAUST ON-VEHICLE SERVICE 7. If the diagnostic trouble code is stored during the check, use scan tool MB991958 to eliminate the diagnosis code. Data link connector MB991910 MB991824 MB991827 AC608435 TURBOCHARGER WASTEGATE ACTUATOR CHECK M1151001200413 1. Connect a hand vacuum pump (pressure-application type) to nipple.

  • Page 7: Intake Charge Pressure Control System Check

    15-7 INTAKE AND EXHAUST ON-VEHICLE SERVICE INTAKE CHARGE PRESSURE CONTROL SYSTEM CHECK M1151001100342 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.

  • Page 8: Turbocharger Waste Gate Solenoid Check

    15-8 INTAKE AND EXHAUST ON-VEHICLE SERVICE TURBOCHARGER WASTE GATE SOLENOID CHECK M1151001300272 No.1 turbocharger wastegate solenoid or brown connector A Operation check 1. Install the hand vacuum pump to the nipple "A" of solenoid. No. 1 turbochager 2. Use the jumper wire to connect the solenoid terminal with wastegate solenoid valve the battery terminal.

  • Page 9: Turbocharger Bypass Valve Check

    15-9 INTAKE AND EXHAUST ON-VEHICLE SERVICE NO.2 turbocharger wastegate solenoid or black connector A Operation check 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.

  • Page 10: Air Cleaner

    15-10 INTAKE AND EXHAUST AIR CLEANER AIR CLEANER REMOVAL AND INSTALLATION M1151002101951 6.0 ± 1.0 N·m 53 ± 9 in-lb 1.5 ± 0.3 N·m 14 ± 2 in-lb 4.0 ± 1.0 N·m 36 ± 8 in-lb 8.5 ± 2.5 N·m 75 ±...
  • Page 11 15-11 INTAKE AND EXHAUST AIR CLEANER INSTALLATION SERVICE POINT >>A<< MASS AIRFLOW SENSOR INSTALLATION CAUTION Do not over-tighten. If the mass airflow sensor installation screw is over-tightened, the air cleaner support thread may be damaged. TSB Revision...

  • Page 12: Intake Manifold

    15-12 INTAKE AND EXHAUST INTAKE MANIFOLD INTAKE MANIFOLD REMOVAL AND INSTALLATION M1151003002723 Pre-removal operation Post-installation operation • Engine Upper Cover Removal (Refer to GROUP 16, Igni- • Fuel Delivery Pipe and Fuel Injector Assembly Installation tion System − Ignition Coil P.16-39). (Refer to GROUP 13A, Injector P.13A-914).
  • Page 13 15-13 INTAKE AND EXHAUST INTAKE MANIFOLD Removal steps (Continued) Control wiring harness connection Engine oil level gauge O-ring >> << Manifold absolute pressure sensor >> << O-ring << >> >> << 10. No.2 Intake air temperature sensor 11. Gasket 12. Vacuum hose connection 13.

  • Page 14: Inspection

    15-14 INTAKE AND EXHAUST INTAKE MANIFOLD >>B<< O-RING/MANIFOLD ABSOLUTE PRESSURE SENSOR INSTALLATION CAUTION • Install the manifold absolute pressure sensor, taking care that no shock is applied to it. • Do not use a manifold absolute pressure sensor that has been dropped. 1.

  • Page 15: Charge Air Cooler

    15-15 INTAKE AND EXHAUST CHARGE AIR COOLER CHARGE AIR COOLER REMOVAL AND INSTALLATION M1151002400410 6.0 ± 1.0 N·m 9.5 ± 3.5 N·m 54 ± 8 in-lb 6.0 ± 1.0 N·m 85 ± 30 in-lb 54 ± 8 in-lb 6.0 ± 1.0 N·m 54 ±...

  • Page 16: Exhaust Manifold And Turbocharger

    15-16 INTAKE AND EXHAUST EXHAUST MANIFOLD AND TURBOCHARGER EXHAUST MANIFOLD AND TURBOCHARGER REMOVAL AND INSTALLATION M1151008900576 Pre-removal operation Post-installation operation • Engine Room Under Cover Front A, B, Engine Room • Cowl Top Panel Installation (Refer to GROUP 42A, Loose Under Cover Center and Engine Room Side Cover (RH) Panel P.42A-15).
  • Page 17 15-17 INTAKE AND EXHAUST EXHAUST MANIFOLD AND TURBOCHARGER 10 ± 2 N·m 89 ± 17 in-lb 7.0 ± 3.0 N·m 62 ± 26 in-lb 10 ± 2 N·m 89 ± 17 in-lb 10 ± 2 N·m 89 ± 17 in-lb 29 ±...
  • Page 18 15-18 INTAKE AND EXHAUST EXHAUST MANIFOLD AND TURBOCHARGER Removal steps (Continued) Turbocharger air outlet fitting gasket <<A>> >> << Turbocharger compressor bracket Turbocharger air inlet fitting Turbocharger air inlet fitting gasket Turbocharger water feed hose 10. Turbocharger water feed pipe 11.
  • Page 19 15-19 INTAKE AND EXHAUST EXHAUST MANIFOLD AND TURBOCHARGER 31 ± 2 N·m 23 ± 1 ft-lb 9.5 ± 2.5 N·m 85 ± 22 in-lb 42 ± 7 N·m 31 ± 5 ft-lb 9.0 ± 1.0 N·m 80 ± 8 in-lb AC710615 Removal steps (Continued) Removal steps...
  • Page 20 15-20 INTAKE AND EXHAUST EXHAUST MANIFOLD AND TURBOCHARGER REMOVAL SERVICE POINTS <<A>> TURBOCHARGER COMPRESSOR BRACKET REMOVAL Use special MB992274 to remove the turbocharger compres- Turbocharger sor bracket mounting bolt (cylinder block side). compressor bracket Turbocharger air inlet fitting MB992274 AC710947AC <<B>>...
  • Page 21 15-21 INTAKE AND EXHAUST EXHAUST MANIFOLD AND TURBOCHARGER >>B<< TURBOCHARGER OIL RETURN TUBE GASKET INSTALLATION Install the gasket as its protrusion is in the direction shown.Install the gasket so that its protrusion faces in the direc- Protrusion tion shown in the illustration. AC706181AC >>C<<...
  • Page 22 15-22 INTAKE AND EXHAUST EXHAUST MANIFOLD AND TURBOCHARGER (3) Use special tool MB991614 to tighten bolts and nuts 65° ± 5° . 65˚ ± 5˚ MB991614 AC711125 >>E<< TURBOCHARGER EXHAUST OUTLET FITTING BRACKET INSTALLATION 1. Check that the turbocharger exhaust outlet fitting bracket is Turbocharger in close contact with the turbocharger exhaust outlet fitting exhaust outlet fitting...

  • Page 23: Inspection

    15-23 INTAKE AND EXHAUST EXHAUST MANIFOLD AND TURBOCHARGER INSPECTION M1151009400132 EXHAUST MANIFOLD CHECK 1. Check the exhaust manifold for damage and cracks, and replace it if necessary. 2. Using a straight edge and a thickness gauge, check for distortion of the cylinder head and turbocharger installation surface.

  • Page 24: Exhaust Pipe And Main Muffler

    15-24 INTAKE AND EXHAUST EXHAUST PIPE AND MAIN MUFFLER EXHAUST PIPE AND MAIN MUFFLER REMOVAL AND INSTALLATION M1151008701854 5.0 ± 2.0 N·m 45 ± 17 in-lb 7.0 ± 3.0 N·m 62 ± 26 in-lb 44 ± 5 N·m 5.0 ± 2.0 N·m 9.5 ±...
  • Page 25 15-25 INTAKE AND EXHAUST EXHAUST PIPE AND MAIN MUFFLER Front floor panel front heat protector and front floor panel rear heat protector removal steps (Continued) Heated oxygen sensor (rear) connector Catalytic converter Cowl side trim (Refer to GROUP • 52A, Trims P.52A-11). Footrest •...
  • Page 26 15-26 INTAKE AND EXHAUST EXHAUST PIPE AND MAIN MUFFLER <<B>> RIVET/FRONT FLOOR REAR PANEL HEAT PROTECTOR/FRONT FLOOR FRONT PANEL HEAT PROTECTOR REMOVAL CAUTION Be careful not to score the heat protector by drill. 1. Use a 6.0 / diameter / mm drill to make a hole in the flange of rivet as shown.

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