Intake & Exhaust - Evolution Mitsubishi Lancer Evolution VIII

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. Refer to «SYMPTOM CHART»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/exhaust/#intake-exhaust-evolution) .
4. Verify malfunction is eliminated.

Scheme 33

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.

Scheme 34

Scheme 35

MANIFOLD VACUUM CHECK

Refer to MANIFOLD VACUUM CHECK .

INTAKE CHARGE PRESSURE CHECK

Scheme 36

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 3,000 r/min at 2nd gear. Measure the intake charge pressure when the pointer is stabilized. Standard value: 53-80 kPa (7.7-11.6 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 37

1. Connect a hand vacuum pump (pressure-application type) to nipple. CAUTION: In order to avoid 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.

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Scheme 39

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. NOTE: If this check indicates an abnormal condition, the turbocharger wastegate solenoid, the turbocharger wastegate actuator, or the hose is broken.

Scheme 40

Scheme 41

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.

COIL RESISTANCE CHECK

Measure resistance between solenoid valve terminals.

Scheme 42

1. Standard value: 29-35 ohm [at 20°C (68°F)]

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Scheme 44

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.

REMOVAL AND INSTALLATION

Scheme 45

1. Avoid any shock or load to these parts when removing and installing them.
2. Engage the case hinges securely when assembling these parts.

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1. After the rubber tubes, the three-way joint, the stop valves and the joint are assembled, affix the clips, the pads and tape to the rubber tubes as shown in illustration.
2. Use the clips and tapes to locate the charge air cooler water spray water hose assembly in position. NOTE: Viewed from inside of front bumper.

Scheme 51

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Scheme 53

1. Check the charge air cooler water spray motor with the charge air cooler water spray tank attached after the tank is supplied with water.
2. Check that the water is supplied with strong pressure after energizing terminal number 1 with battery voltage and grounding terminal number 2.

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<< 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, reinstall 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)

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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 57

<< B >> TURBOCHARGER OIL FEED PIPE REMOVAL

Scheme 58

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 turbocharger 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 (Scheme 59)

Scheme 59

>> C << TURBOCHARGER OIL RETURN PIPE GASKET INSTALLATION

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

Scheme 60

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

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

Scheme 61

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 62

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 63

<< A >> SNAP RING REMOVAL

Remove the compressor cover retaining snap ring using a snap ring pliers.

Scheme 64

<< B >> CARTRIDGE ASSEMBLY REMOVAL

Loosen the cartridge assembly before removal by lightly tapping the compressor cover all around with a plastic hammer.

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CLEANING

1. Use a clean washing solvent available on the market to wash the turbocharger components.
2. Use a plastic scraper or bristle brush for cleaning aluminum parts.

>> A << O-RING INSTALLATION

Smear engine oil on the inside surface of a new O-ring and fit it in the groove of the cartridge assembly.

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Scheme 67

1. Smear engine oil on the inside of the O-ring fitted on the cartridge assembly. CAUTION: Be careful not to damage the vanes of the cartridge assembly when installing the cartridge assembly onto the compressor cover.
2. Install the cartridge assembly onto the compressor cover, aligning the dowel pin with its hole.

>> C << SNAP RING INSTALLATION

Place the set of cartridge assembly and compressor cover upright on the compressor cover and install the snap ring in position.

Scheme 68

>> D << TURBINE HOUSING INSTALLATION

Assemble the set of compressor cover and cartridge assembly with the turbine housing while aligning the dowel pin with its hole.

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Scheme 70

1. Check the turbine housing for turbine wheel contact marks, cracks due to overheating, pitting, deformation, or other kinds of damage. Replace the turbine housing if any crack is found.
2. Operate the waste gate valve lever by hand to check that the valve can be opened and closed smoothly.

COMPRESSOR COVER

Check the compressor cover for compressor wheel contact marks or other damage.

Scheme 71

1. Check the vanes of the turbine and compressor wheel for deformation, damage on edges and other surfaces, corrosion, contact marks on back surfaces, and any other defect. Replace the cartridge assembly if any of the defects is present in the vanes.
2. Check the oil and coolant passages for clogging and damage.

WASTE GATE ACTUATOR

Check that the rod moves when a pressure of the standard value is applied to the actuator using a tester.

1. Standard value: 100 kPa

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Scheme 73

Required Special Tool

1. MD998770: Oxygen sensor wrench

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

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

Scheme 74

>> A << HEATED OXYGEN SENSOR (REAR) INSTALLATION

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

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See also:
• MANIFOLD VACUUM CHECK
• SYMPTOM CHART