Engine Intake System and Exhaust System - Except Lancer Evolution Mitsubishi Lancer Evolution X

GENERAL DESCRIPTION

The exhaust pipe is divided into three parts.

SERVICE SPECIFICATIONS

SERVICE SPECIFICATIONS

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.

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 (Refer to «EXHAUST MANIFOLD < 2.0L ENGINE Non-turbo, 2.4L ENGINE >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/exhaust/#engine-intake-system-and-exhaust-system-except-lancer-evolution) or «EXHAUST PIPE AND MAIN MUFFLER < 2.0L ENGINE Non-turbo, 2.4L ENGINE >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/exhaust/#engine-intake-system-and-exhaust-system-except-lancer-evolution) ). Then go to Step 4 . NO: Go to Step 3.
3. STEP 3. Check for loosening in each coupling section. Q: Is there any loosening in any section? YES: Tighten the loosening section (Refer to «EXHAUST MANIFOLD < 2.0L ENGINE Non-turbo, 2.4L ENGINE >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/exhaust/#engine-intake-system-and-exhaust-system-except-lancer-evolution) or «EXHAUST PIPE AND MAIN MUFFLER < 2.0L ENGINE Non-turbo, 2.4L ENGINE >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/exhaust/#engine-intake-system-and-exhaust-system-except-lancer-evolution) ). Then go to Step 4. NO: There is no action to be taken.
4. STEP 4. 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: Return to Step 2 . NO: The procedure is complete.

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 abnormal noise. 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 the muffler (Refer to «EXHAUST PIPE AND MAIN MUFFLER < 2.0L ENGINE Non-turbo, 2.4L ENGINE >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/exhaust/#engine-intake-system-and-exhaust-system-except-lancer-evolution) ). Then go to Step 7 . NO: Go to Step 3.
3. STEP 3. Check the hanger for cracks. Q: Is the hanger cracked? YES: Replace the hanger (Refer to «EXHAUST PIPE AND MAIN MUFFLER < 2.0L ENGINE Non-turbo, 2.4L ENGINE >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/exhaust/#engine-intake-system-and-exhaust-system-except-lancer-evolution) ). Then go to Step 7 . 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 the pipes or muffler. Then go to Step 7 . NO: Go to Step 5.
5. STEP 5. Check the heat protectors. Q: Are any heat protectors loose or damaged? YES: Tighten or replace the heat protector (Refer to «EXHAUST PIPE AND MAIN MUFFLER < 2.0L ENGINE Non-turbo, 2.4L ENGINE >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/exhaust/#engine-intake-system-and-exhaust-system-except-lancer-evolution) ). Then go to Step 7 . NO: Go to Step 6.
6. STEP 6. Check the pipes and muffler for damage. Q: Are the pipes and muffler damaged? YES: Replace the pipes or muffler (Refer to «EXHAUST PIPE AND MAIN MUFFLER < 2.0L ENGINE Non-turbo, 2.4L ENGINE >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/exhaust/#engine-intake-system-and-exhaust-system-except-lancer-evolution) ). Then go to Step 7. NO: There is no action to be taken.
7. STEP 7. 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 abnormal noise. Q: Is any abnormal noise generated? YES: Return to Step 2 . NO: The procedure is complete.

SPECIAL TOOLS

SPECIAL TOOLS Tool Tool number and name Supersession Application MB992188 Fuel injection pipe wrench MB992188-01 Removal and installation of number 2 air temperature sensor < 2.0L ENGINE Turbo > MB991614 Angle gauge General service tool Installation of turbocharger assembly coupling bolt < 2.0L ENGINE Turbo > MB991953 Oxygen sensor wrench MB991953-01 Removal and installation of linear air-fuel ratio sensor or heated oxygen sensor

Scheme 1

Scheme 2

TROUBLESHOOTING

TROUBLESHOOTING SYMPTOM CHART

Scheme 3

1. Disconnect the hose (black) from the turbocharger wastegate solenoid, and connect the pressure gauge to the hose. Cap the solenoid valve nipple after the hose (black) was disconnected. CAUTION: Two persons should be in the vehicle when the test is conducted; the person in the passenger seat should read the indications shown by the pressure meter.
2. Drive at full-throttle acceleration in second gear and then measure the intake charge pressure when the engine speed is about 3,000 r/min or more. Standard value: 68 - 122 kPa (9.9 - 17.6 psi)
3. If the intake charge pressure is lower than the standard value, check the following items for possible causes. Turbocharger wastegate actuator malfunction Turbocharger wastegate regulating valve malfunction Intake charge pressure leakage Turbocharger malfunction Turbocharger bypass valve malfunction
4. When the intake charge pressure is higher than standard value, the intake charge control may be faulty. Therefore check the followings: Turbocharger wastegate actuator malfunction Turbocharger wastegate regulating valve malfunction Rubber hose of turbocharger wastegate actuator disconnected or cracked

Scheme 4

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 94 kPa (13.6 psi) or higher.
2. While gradually applying pressure, check the pressure that begins to activate (approximately 1 mm stroke) the turbocharger wastegate actuator rod. Standard value: 78 - 82 kPa (11.4 - 11.8 psi)
3. If there is a significant deviation from the standard value, check the actuator or the turbocharger wastegate regulating valve: replace if necessary.

Scheme 5

Scheme 6

1. Disconnect the hose (black) from the turbocharger wastegate solenoid and connect a three way joint between the hose and the solenoid valve.
2. Connect a hand pump (pressurized type) to the three-way joint.
3. Use the turbocharger wastegate actuator control boost nipple of air outlet fitting to disconnect the boost hose. Plug this nipple. CAUTION: Do not apply the pressure of 94 kPa or more to prevent the diaphragm damage.
4. Applying a pressure with the hand pump, check tightness both when the hose end is closed and when it is open. ENGINE STATE AND HOSE END STATUS Engine state Hose end Normal state Stop (Ignition switch: ON position) Opened Pressure leaks. Closed Pressure is maintained. Rapid racing Pressure leaks.
5. Turn the ignition switch to "LOCK" (OFF) position.

Scheme 7

Scheme 8

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 STATUS Jumper wire Nipple "B" state Normal state Connected Opened Negative pressure leaks Closed Negative pressure maintained Disconnected Opened Negative pressure maintained

Scheme 9

1. Measure the resistance between the solenoid terminals. Standard value: 29 - 35 ohms at 20°C (68°F)

Scheme 10

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 50 kPa (14.8 in. Hg) and check that air tightness is maintained.
4. Also check operation of the valve. NEGATIVE PRESSURE SPECIFICATION Negative pressure Valve operation 50.8 - 66.8 kPa (15.0 - 19.7 in. Hg) It starts opening

Scheme 11

>> A << MASS AIRFLOW SENSOR INSTALLATION

Scheme 12

Scheme 13

<< A >> AIR HOSE/AIR PIPE REMOVAL

Put mating marks on the air hose, air pipe, and hose clamp, and remove them.

Scheme 14

Scheme 15

Scheme 16

1. Insert hose to stopper end and not overlap with stopper.
2. Place the hose clamp as shown in the figure so that it does not overlap with the bulge and the stopper end. Then, set the hose clamp 5 ± 1 mm (0.20 ± 0.04 inch) away from the stopper. CAUTION: Do not use an electric screwdriver or air tool. Manually tighten the hose clamp.
3. Align the mating marks on the air hose, air pipe, and hose clamp. Then, tighten the hose clamp to the specified torque. Tightening torque: 6.0 ± 1.0 N.m (54 ± 8 in-lb)

Scheme 17

>> A << O-RING/PURGE CONTROL SOLENOID VALVE/O-RING/MANIFOLD ABSOLUTE PRESSURE SENSOR INSTALLATION

1. Apply a small amount of new engine oil to the O-ring.
2. While turning the purge control solenoid valve or manifold absolute pressure sensor to right and left, install the O-ring to the purge control solenoid valve or manifold absolute pressure sensor with care to avoid damage to the O-ring.
3. Turning the purge control solenoid valve or manifold absolute pressure sensor to right and left, install it to the intake manifold with care not to damage the O-ring. After the installation, check for its smooth rotation.

>> B << SCREW INSTALLATION

>> C << INTAKE MANIFOLD ASSEMBLY/INJECTOR PROTECTOR FRONT INSTALLATION

Install the intake manifold assembly and the injector protector front, and tighten mounting bolts and nuts temporarily.

Note. The tightening of the fuel rail assembly, the intake manifold assembly and the injector protector front has the specified order. Temporarily tighten the intake manifold assembly and injector protector front mounting bolts and nuts (Refer to INJECTOR ) < 2.0L ENGINE Non-turbo > or (Refer to INJECTOR ) < 2.4L ENGINE >.

Scheme 18

Required Special Tool

1. MB992188: Fuel Injection Pipe Wrench

<< A >> NUMBER 2 INTAKE AIR TEMPERATURE SENSOR REMOVAL

Use special tool MB992188 to remove the number 2 intake air temperature sensor.

Scheme 19

>> A << NUMBER 2 INTAKE AIR TEMPERATURE SENSOR INSTALLATION

Tighten the number 2 intake air temperature sensor to the specified torque by using special tool MB992188.

Tightening torque: 14 ± 1 N.m (120 ± 13 in-lb)

>> B << O-RING/MANIFOLD ABSOLUTE PRESSURE SENSOR INSTALLATION

1. Apply a small amount of new engine oil to the O-ring.
2. Install the manifold absolute pressure sensor to the intake manifold with care not to damage the O-ring.

INTAKE MANIFOLD CHECK

1. Check the intake manifold for damage and cracks, and replace it if necessary.
2. Check the vacuum outlet port for clogging, and clean it if necessary.

Scheme 20

Scheme 21

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 installation surface. If it exceeds the limit value, replace it. Limit: 0.70 mm (0.028 inch)

Scheme 22

Scheme 23

Required Special Tools

1. MB991614: Angle Gauge

<< A >> TURBOCHARGER OIL FEED TUBE REMOVAL

>> A << TURBOCHARGER INSTALLATION

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

Scheme 24

1. Check that the turbocharger bracket is in close contact with the turbocharger assembly and with the cylinder block. Then, temporarily tighten the turbocharger bracket mounting bolts, the turbocharger bracket and the turbocharger assembly coupling bolts.
2. Tighten the turbocharger bracket mounting bolts to the specified torque. Tightening torque: 51 ± 7 N.m (38 ± 5 ft-lb)
3. Tighten the turbocharger bracket and turbocharger assembly coupling bolt to the specified torque. Tightening torque: 64 ± 5 N.m (48 ± 3 ft-lb)

Scheme 25

Scheme 26

1. Tighten the bolts and nuts according to the procedure below. Install two washers with their identification holes facing outside as shown in the figure. Tighten the bolts and nuts to the specified torque. Tightening torque: 29 ± 2 N.m (22 ± 1 ft-lb) CAUTION: When the tightening angle is smaller than the specified tightening angle, the appropriate tightening capacity cannot be secured. When the tightening angle is larger than the specified tightening angle, remove the bolt and nut to start from the beginning again according to the procedure. Use special tool MB991614 to tighten bolts and nuts 65 ± 5 degrees angle.

>> D << TURBOCHARGER OIL RETURN TUBE GASKET INSTALLATION

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

Scheme 27

Scheme 28

1. Check that the turbocharger exhaust outlet fitting bracket is in close contact with the turbocharger exhaust outlet fitting and with the cylinder block, and then temporarily tighten the turbocharger exhaust outlet fitting bracket mounting bolts.
2. Tighten the bolt of the cylinder block side to the specified torque. Tightening torque: 51 ± 7 N.m (38 ± 5 ft-lb)
3. Tighten the bolt of the turbocharger exhaust outlet fitting bracket side to the specified torque. Tightening torque: 64 ± 5 N.m (48 ± 3 ft-lb)

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. If it exceeds the limit value, replace it. Limit < Cylinder head assembly side >: 0.70 mm (0.028 inch) Limit < Turbocharger assembly side >: 0.40 mm (0.016 inch)

TURBOCHARGER ASSEMBLY CHECK

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 waste gate regulating valve remains open. If any problem is found, replace the part after disassembly.

Scheme 29

Required Special Tool

1. MB991953: Oxygen Sensor Wrench

<< A >> LINEAR AIR-FUEL RATIO SENSOR/HEATED OXYGEN SENSOR REMOVAL

Use special tool MB991953 to remove the heated oxygen sensor.

Scheme 30

<< B >> RIVET REMOVAL

Use a 6.0/diameter/mm drill to make a hole in the rivet to break it, and then remove the rivet.

Scheme 31

>> A << RIVET INSTALLATION

Use a rivet tool shown in the illustration to connect the parts with rivets by the following procedures.

Scheme 32

1. Insert the rivet into a corresponding location.
2. Set the rivet tool at a portion A of rivet.
3. While pushing the flange surface of the rivet onto parts to be fixed with the rivet tool, press the handle of the tool.
4. Thin part of portion A of the rivet will be cut off and the parts is fixed in position.

>> B << LINEAR AIR-FUEL RATIO SENSOR/HEATED OXYGEN SENSOR INSTALLATION

Tighten the heated oxygen sensor to the specified torque by using special tool MB991953.

Tightening torque: 44 ± 5 N.m (33 ± 3 ft-lb)

>> C << EXHAUST TAIL PIPE DIFFUSER INSTALLATION

When the part is reused, make sure that there is no excessive play after installation and that the part is securely fixed.

Scheme 33

Required Special Tool

1. MB991953: Oxygen Sensor Wrench

<< A >> HEATED OXYGEN SENSOR REMOVAL

Use special tool MB991953 to remove the heated oxygen sensor.

Use a 6.0/diameter/mm drill to make a hole in the rivet to break it, and then remove the rivet.

Use a rivet tool shown in the illustration to connect the parts with rivets by the following procedures.

1. Insert the rivet into a corresponding location.
2. Set the rivet tool at a portion A of rivet.
3. While pushing the flange surface of the rivet onto parts to be fixed with the rivet tool, press the handle of the tool.
4. Thin part of portion A of the rivet will be cut off and the parts is fixed in position.

>> B << HEATED OXYGEN SENSOR INSTALLATION

Tighten the heated oxygen sensor to the specified torque by using special tool MB991953.

Tightening torque: 44 ± 5 N.m (33 ± 3 ft-lb)

When the part is reused, make sure that there is no excessive play after installation and that the part is securely fixed.

See also:
• INJECTOR
• INJECTOR
• INSPECTION PROCEDURE 1: EXHAUST LEAKAGE