Intake and Exhaust - Lancer Evolution Mitsubishi Lancer Evolution IX

GENERAL DESCRIPTION

The exhaust pipe is divided into three parts.

INTRODUCTION

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 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 the system contacts the body and vibration noise is generated.

TROUBLESHOOTING 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 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

SYMPTOM CHART

DIAGNOSIS

1. 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.
2. STEP 2. Check the gasket for cracks, damage. Q: Is the gasket damaged? YES: Replace the gasket, then go Step 1 . NO: Go to Step 3.
3. STEP 3. Check for loosening in each coupling section. Q: Is there any loosening in each section? YES: Tighten, then go to Step 1 . NO: There is no action to be taken.

1. 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.
2. 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.
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.
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.
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.
6. STEP 6. Check the pipes, catalytic converters and muffler for damage. Q: Are the pipes, catalytic converters and muffler damaged? YES: Replace, then go to Step 1 . NO: There is no action to be taken.

SPECIAL TOOL

SPECIAL TOOL TOOL TOOL NUMBER AND NAME SUPERSESSION APPLICATION MD998770 Oxygen sensor wrench MD998770-01 or General service tool Removal and installation of heated oxygen sensor

Scheme 17

TROUBLESHOOTING

TROUBLESHOOTING SPECIFICATION

MANIFOLD VACUUM CHECK

Refer to MANIFOLD VACUUM CHECK .

INTAKE CHARGE PRESSURE CHECK

Scheme 18

1. Disconnect the hose (black) from the tee-fitting joint and connect the pressure gauge to this joint. Plug the hose (black).
2. Drive the vehicle with full throttle and accelerate the engine to a speed of more than 3,500 r/min at 2nd gear. Measure the intake charge pressure when the pointer is stabilized. Standard value: 112 - 139 kPa (16.2 - 20.2 psi)
3. If the intake charge pressure is lower than the standard value, check the following items for possible cause. Malfunction of turbocharger wastegate actuator. Intake charge pressure leaks. Faulty turbocharger.
4. If the intake charge pressure is higher than the standard value, the intake charge pressure control may be faulty. Therefore check the following. Malfunction of turbocharger wastegate actuator. Malfunction of turbocharger wastegate regulating valve. Disconnected or cracked turbocharger wastegate actuator hose.

Scheme 19

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: Approximately 100 kPa (15 psi)
3. If there is a significant deviation from the standard value, check the actuator or the wastegate valve: replace if necessary.

Scheme 20

1. After the diagnostic trouble code of MFI system is read, turn off the ignition switch.
2. Disconnect the hose (black) from the turbocharger wastegate actuator control boost nipple at the air outlet fitting and plug this nipple.
3. Connect a hand vacuum pump to the hose (black).
4. Use the vacuum pump to apply negative pressure, and check the negative pressure condition while the engine is stopped and while it is idling. ENGINE SPECIFICATION Engine state Normal state Stop (Ignition switch: "ON" (position) Negative pressure is maintained Idle (after warm-up) Negative pressure leaks NOTE: If this check indicates an abnormal condition, the turbocharger wastegate solenoid, the turbocharger wastegate actuator, or the hose is broken.

Scheme 21

1. Connect a hand vacuum pump to the solenoid valve nipple A.
2. Use a jumper wire to connect between the solenoid valve terminal and battery terminal.
3. Connect and disconnect the jumper wire at the battery negative terminal to apply negative pressure and check tightness. JUMPER WIRE REFERENCE CHART Jumper wire B nipple condition Normal state Connected Open Negative pressure leaks. Close Negative pressure is held. Disconnected Open Negative pressure is held.

COIL RESISTANCE CHECK

Measure resistance between solenoid valve terminals.

Standard value: 29 - 35 +/- [at 20° C (68° F)]

Scheme 22

Scheme 23

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 53 kPa (15.7 in.Hg) and check operation of the valve. Also check that air tightness is maintained. VALVE OPERATION CHART Negative pressure Valve operation Approximately 53 kPa (15.7 in.Hg) Starts opening

REMOVAL AND INSTALLATION

Note. Parts marked by * are made of recycled-paper mixed plastic material. Dispose of according to state and local laws

Scheme 24

Scheme 25

Scheme 26

Scheme 27

<< A >> FUEL RAIL, FUEL INJECTOR, FUEL RETURN PIPE AND FUEL PRESSURE REGULATOR ASSEMBLY REMOVAL

The fuel rail must be removed with the fuel injector, fuel return pipe and fuel pressure regulator attached.

>> A << FUEL HIGH-PRESSURE HOSE INSTALLATION

1. Apply a drop of new engine oil to the O-ring.
2. Turn the fuel high-pressure hose to the right and left to install to the fuel rail. Be careful not to damage the O-ring. After installing, check that the fuel high-pressure hose turns smoothly.
3. If the fuel high-pressure hose does not turn smoothly, the O-ring may be trapped. Remove the fuel high-pressure hose, re-install the fuel high-pressure hose into the fuel rail and check again.
4. Tighten the fuel high-pressure hose to the specified torque. Tightening torque: 5.0 +/- 1.0 N. m (44 +/- 9 in-lb)

INSPECTION

Check the following points; replace the part if a problem is found.

Intake Manifold Check

1. Check for damage or cracking of any part.
2. Clogging of the negative pressure (vacuum) outlet port, or clogging of the exhaust gas recirculation passages.
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)

Scheme 28

Required Special Tool

1. MD998770: Oxygen Sensor Wrench

<< A >> HEATED OXYGEN SENSOR (FRONT) REMOVAL

Use special tool MD998770 to remove the heated oxygen sensor (front).

Scheme 29

<< B >> TURBOCHARGER OIL FEED PIPE REMOVAL

Scheme 30

1. Clean the oil pipe and water pipe fitting, the inside of eye bolts, and individual pipe for clogs. CAUTION: Take care not to allow foreign objects to get into the turbo-charger assembly.
2. Clean or use compressed air to remove any carbon particles stuck to the oil passage of the turbocharger assembly.
3. Refill new engine oil at the oil feed pipe fitting hole of the turbocharger assembly.

>> B << AIR OUTLET FITTING GASKET INSTALLATION

Install the gasket so that its protrusion faces in the direction shown in the illustration.

Scheme 31

>> C << TURBOCHARGER OIL RETURN PIPE GASKET INSTALLATION

Install the gasket so that its protrusion faces in the direction shown in the illustration.

Scheme 32

>> D << HEATED OXYGEN SENSOR (FRONT) INSTALLATION

Use special tool MD998770 to install the heated oxygen sensor (front).

Check the following points; replace the part if a problem is found.

Exhaust Manifold 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)

Scheme 33

1. Visually check the turbine wheel and the compressor wheel for cracking or other damage.
2. Check whether the turbine wheel and the compressor wheel can be easily turned by hand.
3. Check for oil leakage from the turbocharger assembly.
4. Check whether or not the turbocharger wastegate regulating valve remains open. If any problem is found, replace the part after disassembly.

Scheme 34

FASTENER TIGHTENING SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

SERVICE SPECIFICATION

SERVICE SPECIFICATION

See also:
• MANIFOLD VACUUM CHECK
• 1