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 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
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.
- Gather information from the customer.
- Verify that the condition described by the customer exists.
- Find the malfunction by following «SYMPTOM CHART»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/exhaust/#intake-exhaust-except-evolution-sportback) .
- Verify malfunction is eliminated.
Scheme 15
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 Step 1 . NO : Go to Step 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.
- 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.
Scheme 16
REMOVAL AND INSTALLATION
| CAUTION | Parts marked by * are made of recycled-paper mixed plastic material, so observe the following precautions. Avoid any shock or load to these parts when removing and installing them. When installing, securely set the air cleaner housing cover clamp to the air cleaner housing. |
Note. Parts marked by * are made of recycled-paper mixed plastic material. Dispose of according to state and local laws
Scheme 17
Scheme 18
Scheme 19
Scheme 20
Scheme 21
<< A >> RADIATOR LOWER HOSE DISCONNECTION
Make mating marks on the radiator hose and the hose clamp. Disconnect the radiator hose.
Scheme 22
Scheme 23
- Use a gasket scraper or wire brush to completely eliminate all gasket material on the gasket mounting surface.
- Apply a bead of the sealant to the cylinder head mating surface of the thermostat case as shown. Specified Sealant: 3M TM AAD part No.8672, 3M TM AAD part No.8679/8678 or equivalent
- Apply sealant to the thread of the thermostat case assembly bolts as shown. Specified Sealant: 3M TM AAD part No.4170 or equivalent
- With the sealant still wet (within 15 minutes after the sealant is applied), install the thermostat case. Do not apply the sealant in an area more than the required.
Scheme 24
- Insert each hose as far as the projection of the water inlet fitting.
- Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose.
INSPECTION
Check the following points; replace the part if a problem is found.
INTAKE MANIFOLD CHECK
- Check for damage or cracking of any part.
- Clogging of the negative pressure (vacuum) outlet port, or clogging of the exhaust gas recirculation passages.
- 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 25
<< A >> POWER STEERING OIL PUMP AND BRACKET ASSEMBLY REMOVAL
With the hose installed, remove power steering oil pump and bracket assembly.
Note. Tie the removed power steering oil pump and bracket assembly, with strings at a position where they will not interfere with the installation or removal of the exhaust manifold.
Scheme 26
Check the following points; replace the part if a problem is found.
EXHAUST MANIFOLD CHECK
- Check for damage or cracking of any part.
- 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 27
Scheme 28
<< A >> HEATED OXYGEN SENSOR (REAR)/HEATED OXYGEN SENSOR (FRONT) REMOVAL
Use special tool MD998770 to remove the oxygen sensor.
Scheme 29
>>A<< HEATED OXYGEN SENSOR (FRONT)/HEATED OXYGEN SENSOR (REAR) INSTALLATION
Use special tool MD998770 to install the oxygen sensor.
Scheme 30
FASTENER TIGHTENING SPECIFICATIONS
| ITEM | SPECIFICATION | |
|---|---|---|
| Air cleaner <2.0L ENGINE> | ||
| Air cleaner bolt | 8.8 ± 1.0 N.m (78 ± 9 in-lb) | |
| Air cleaner bracket bolt | 11 ± 1 N.m (97 ± 9 in-lb) | |
| Air flow sensor assembly nut | 8.8 ± 1.0 N.m (78 ± 9 in-lb) | |
| Air intake hose clamp bolt | 3.9 ± 1.0 N.m (35 ± 8 in-lb) | |
| Air cleaner <2.4L ENGINE> | ||
| Air cleaner bracket bolt | 11 ± 1 N.m (98 ± 8 in-lb) | |
| Air cleaner housing assembly bolt | 8.8 ± 1.0 N.m (78 ± 9 in-lb) | |
| Air intake hose clamp bolt | 3.9 ± 1.0 N.m (35 ± 8 in-lb) | |
| Mass airflow sensor assembly bolt | 1.8 ± 0.6 N.m (16 ± 5 in-lb) | |
| Exhaust manifold <2.0L ENGINE> | ||
| Exhaust manifold bracket bolt | M8 | 19 ± 3 N.m (14 ± 2 ft-lb) |
| M10 | 35 ± 6 N.m (26 ± 4 ft-lb) | |
| Exhaust manifold nut | M8 | 17 ± 2 N.m (12 ± 2 ft-lb) |
| M10 | 30 ± 3 N.m (22 ± 2 ft-lb) | |
| Front exhaust pipe nut | 50 ± 10 N.m (37 ± 7 ft-lb) | |
| Heat protector bolt | 13 ± 1 N.m (115 ± 9 in-lb) | |
| Heated oxygen sensor | 44 ± 5 N.m (33 ± 3 ft-lb) | |
| Power steering pump bracket stay bolt | 49 ± 9 N.m (36 ± 7 ft-lb) | |
| Power steering oil pump and bracket assembly bolt | M8 | 22 ± 4 N.m (16 ± 3 ft-lb) |
| M10 | 44 ± 10 N.m (33 ± 7 ft-lb) | |
| Pressure hose clamp bolt | 12 ± 2 N.m (102 ± 22 in-lb) | |
| Exhaust manifold <2.4L ENGINE> | ||
| Exhaust manifold nut | 49 ± 5 N.m (36 ± 4 ft-lb) | |
| Front exhaust pipe nut | 50 ± 10 N.m (37 ± 7 ft-lb) | |
| Front exhaust pipe bracket bolt | 35 ± 5 N.m (26 ± 4 ft-lb) | |
| Heat protector bolt | 14 ± 1 N.m (120 ± 13 in-lb) | |
| Exhaust pipe and main muffler <2.0L ENGINE> | ||
| Center exhaust pipe bolt | 45 ± 5 N.m (34 ± 3 ft-lb) | |
| Center exhaust pipe nut | 59 ± 10 N.m (44 ± 7 ft-lb) | |
| Front exhaust pipe nut | 50 ± 10 N.m (37 ± 7 ft-lb) | |
| Hanger bolt | 13 ± 2 N.m (111 ± 22 in-lb) | |
| Heated oxygen sensor | 44 ± 5 N.m (33 ± 3 ft-lb) | |
| Exhaust pipe and main muffler <2.4L ENGINE> | ||
| Center exhaust pipe bolt | 45 ± 5 N.m (34 ± 3 ft-lb) | |
| Center exhaust pipe nut | 59 ± 10 N.m (44 ± 7 ft-lb) | |
| Front exhaust pipe bracket bolt | 35 ± 5 N.m (26 ± 4 ft-lb) | |
| Front exhaust pipe nut | 50 ± 10 N.m (37 ± 7 ft-lb) | |
| Hanger bolt | 13 ± 2 N.m (111 ± 22 in-lb) | |
| Heated oxygen sensor (front) | 45 ± 5 N.m (34 ± 3 ft-lb) | |
| Heated oxygen sensor (rear) | 45 ± 5 N.m (34 ± 3 ft-lb) | |
| Intake manifold <2.0L ENGINE> | ||
| EGR valve bolt | 22 ± 4 N.m (16 ± 3 ft-lb) | |
| Engine hanger bolt | 24 ± 3 N.m (18 ± 2 ft-lb) | |
| Intake manifold bolt and nut | 19 ± 3 N.m (14 ± 2 ft-lb) | |
| Intake manifold stay bolt | 31 ± 3 N.m (23 ± 2 ft-lb) | |
| Manifold absolute pressure sensor bolt | 5.0 ± 1.0 N.m (44 ± 9 in-lb) | |
| Throttle body stay bolt | 24 ± 3 N.m (18 ± 2 ft-lb) | |
| Vacuum hose and pipe assembly bolt | 11 ± 1 N.m (98 ± 8 in-lb) | |
| Vacuum pipe bolt | 5.0 ± 1.0 N.m (45 ± 8 in-lb) | |
| Intake manifold <2.4L ENGINE> | ||
| Brake booster vacuum pipe bolt | 13 ± 2 N.m (111 ± 22 in-lb) | |
| EGR valve bolt | 24 ± 3 N.m (18 ± 2 ft-lb) | |
| Engine hanger bolt | 24 ± 3 N.m (18 ± 2 ft-lb) | |
| Evaporative emission purge solenoid valve, evaporative emission vacuum hose and pipe assembly bolt | 11 ± 1 N.m (98 ± 8 in-lb) | |
| Exhaust gas recirculation valve bolt | 24 ± 3 N.m (18 ± 2 ft-lb) | |
| Harness cramp bolt | 11 ± 1 N.m (98 ± 8 in-lb) | |
| Intake manifold bolt | 24 ± 3 N.m (18 ± 2 ft-lb) | |
| Intake manifold nut | 20 ± 2 N.m (15 ± 1 ft-lb) | |
| Intake manifold stay bolt | 31 ± 3 N.m (23 ± 2 ft-lb) | |
| Knock sensor connector cramp bolt | 11 ± 1 N.m (98 ± 8 in-lb) | |
| Manifold absolute pressure sensor bolt | 5.0 ± 1.0 N.m (44 ± 9 in-lb) | |
| Oil dipstick guide bolt | 13 ± 1 N.m (115 ± 9 in-lb) | |
| Thermostat case assembly bolt | 24 ± 4 N.m (18 ± 3 ft-lb) | |
FASTENER TIGHTENING SPECIFICATIONS
Scheme 31
Scheme 32
See also:
• SYMPTOM CHART