Mitsubishi EVO X Operating instructions

15-1
GROUP 15
INTAKE AND
EXHAUST
CONTENTS
GENERAL INFORMATION . . . . . . . . 15-2
SERVICE SPECIFICATION . . . . . . . . 15-2
INTAKE AND EXHAUST DIAGNOSIS 15-2
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . 15-2
TROUBLESHOOTING STRATEGY . . . . . . 15-2
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 15-2
SYMPTOM PROCEDURES . . . . . . . . . . . . 15-3
SPECIAL TOOLS. . . . . . . . . . . . . . . . 15-4
TROUBLESHOOTING . . . . . . . . . . . . 15-4
ON-VEHICLE SERVICE. . . . . . . . . . . 15-5
MANIFOLD VACUUM CHECK . . . . . . . . . . 15-5
INTAKE CHARGE PRESSURE CHECK . . 15-5
TURBOCHARGER WASTEGATE ACTUATOR
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6
INTAKE CHARGE PRESSURE CONTROL
SYSTEM CHECK . . . . . . . . . . . . . . . . . . . . 15-7
TURBOCHARGER WASTE GATE SOLENOID
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-8
TURBOCHARGER BYPASS VALVE
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-9
AIR CLEANER . . . . . . . . . . . . . . . . . . 15-10
REMOVAL AND INSTALLATION . . . . . . . . 15-10
INTAKE MANIFOLD . . . . . . . . . . . . . . 15-12
REMOVAL AND INSTALLATION . . . . . . . . 15-12
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 15-14
CHARGE AIR COOLER . . . . . . . . . . . 15-15
REMOVAL AND INSTALLATION . . . . . . . . 15-15
EXHAUST MANIFOLD AND
TURBOCHARGER . . . . . . . . . . . . . . . 15-16
REMOVAL AND INSTALLATION . . . . . . . . 15-16
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 15-23
EXHAUST PIPE AND MAIN
MUFFLER . . . . . . . . . . . . . . . . . . . . . . 15-24
REMOVAL AND INSTALLATION . . . . . . . . 15-24

GENERAL INFORMATION
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INTAKE AND EXHAUST
15-2
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)
Intake charge pressure kPa (psi) 85 −159 (12.4 −23.0) −
Turbocharger waste gate actuator pressure kPa (psi) 98 −102 (14.3 −14.7) −
No. 1 Turbocharger waste gate solenoid terminal
resistance [at 20°C (68°F) ] Ω
29 −35 −
No. 2 Turbocharger waste gate solenoid terminal
resistance [at 20°C (68°F) ] Ω
29 −35 −
Exhaust manifold distortion of the installation surface
mm (in)
−0.70 (0.028)
INTAKE AND EXHAUST DIAGNOSIS
INTRODUCTION M1151006900406
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 M1151007000398
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 M1151007100395
Symptom Inspection procedure Reference page
Exhaust Leakage 1P.15-3
Abnormal Noise 2P.15-3

INTAKE AND EXHAUST DIAGNOSIS
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INTAKE AND EXHAUST 15-3
SYMPTOM PROCEDURES
Inspection Procedure 1: Exhaust Leakage
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 to Step 1.
NO : Go to Step 3.
STEP 3. Check for loosening in each coupling
section.
Q: Is there any loosening in any section?
YES : Tighten, then go to Step 1.
NO : There is no action to be taken.
Inspection Procedure 2: Abnormal Noise
DIAGNOSIS
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.

SPECIAL TOOLS
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INTAKE AND EXHAUST
15-4
SPECIAL TOOLS
M1151000601024
Tool Tool number and name Supersession Application
B992274
MB992274
Palm socket
-Removal and installation
of turbocharger
compressor bracket
MB991614
MB991614
Angle gauge
General service tool Installation of
turbocharger assembly
coupling bolt and nut
B991953
MB991953
Oxygen sensor wrench
MB991953-01 Removal and installation
of heated oxygen sensor
MB992188
Fuel injection pipe
wrench
MB992188-01 Removal and installation
of No.2 air temperature
sensor
TROUBLESHOOTING
M1151010200035
Symptom Probable cause Remedy
Exhaust gas leakage Loose joints Retighten
Broken pipe or muffler Repair or replace
Abnormal noise Broken baffle in muffler Replace
Broken rubber hangers Replace
Interference of pipe or muffler with vehicle
body
Correct
Broken pipe or muffler Repair or replace

ON-VEHICLE SERVICE
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INTAKE AND EXHAUST 15-5
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
AK703282
Cap
AC
No. 1 turbocharger
wastegate solenoid
1. Removing the black hose from the No.1 turbocharger
wastegate solenoid or the brown connector, install the
pressure gauge to this hose. Cap the nipple of solenoid after
removing the black hose.
AK703283 AC
No. 2 turbochager
wastegate solenoid
2. Disconnect the black connector of No.2 turbocharger
wastegate solenoid.
3. When the engine speed reaches approximately 3000r/min
or more with the throttle fully opened in the second gear,
measure the boost pressure.
Standard value: 85 −159kPa (12.4 −23.0 psi)
4. If the boost pressure is lower than the standard, check the
following possible causes.
a. Turbocharger wastegate actuator malfunction
b. Boost pressure leakage
c. Turbocharger malfunction
5. If the boost pressure is higher than the standard, check on
the following areas because the boost pressure control
might be abnormal.
a. Turbocharger wastegate actuator malfunction
b. Wastegate regulating valve malfunction
c. Rubber hose of turbocharger wastegate actuator discon-
nected or cracked
AK703283 AC
No. 2 turbochager
wastegate solenoid
6. Connect the black connector of No.2 turbocharger
wastegate solenoid.

AC608435
Data link connector
MB991827
MB991824
MB991910
AB
ON-VEHICLE SERVICE
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INTAKE AND EXHAUST
15-6
7. If the diagnostic trouble code is stored during the check, use
scan tool MB991958 to eliminate the diagnosis code.
TURBOCHARGER WASTEGATE ACTUATOR
CHECK M1151001200413
AK703279AC
Turbochager wastegate actuator
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: 98 −102 kPa (14.3 −14.7 psi)
3. If there is a significant deviation from the standard value,
check the actuator or the wastegate valve: replace if
necessary.

ON-VEHICLE SERVICE
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INTAKE AND EXHAUST 15-7
INTAKE CHARGE PRESSURE CONTROL SYSTEM
CHECK M1151001100342
AK703284
Three-way joint
AC
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.
AK703105
Boost hose
Turbochager
wastegate actuator
AC
3. Use the turbocharger wastegate actuator control boost
nipple of air outlet fitting to remove the boost hose. Plug this
nipple.
CAUTION
Do not apply the pressure of 117kPA or more to prevent
the diaphragm damage.
4. Blocking or releasing the boost hose end, apply the
pressure. Check the pressurized state.
Engine state Boost hose end Normal state
Stopped: Ignition
switch in "ON"
position
Opened Pressure leaks
Closed Pressure
maintained
Rapid racing Pressure leaks
5. Put the ignition switch in "LOCK" (OFF) position.
AK703285AC
No. 1 turbochager
wastegate solenoid valve
6. Disconnect the connector of No.1 turbocharger wastegate
solenoid or the brown connector.
7. Blocking or releasing the boost hose end, apply the
pressure. Check the pressurized state. Plug the boost hose
end while driving.
Engine state Boost hose end Normal state
Stopped: Ignition
switch in "ON"
position
Opened Pressure leaks
Closed Pressure
maintained
4000r/min after
warming up
engine
Pressure leaks
NOTE: Unless the pressurized state is normal, the turbo-
charger wastegate actuator, turbocharger wastegate solenoid
or the hose might have a malfunction.

ON-VEHICLE SERVICE
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INTAKE AND EXHAUST
15-8
TURBOCHARGER WASTE GATE SOLENOID
CHECK M1151001300272
No.1 turbocharger wastegate solenoid or brown
connector
.
A Operation check
AK703285AC
No. 1 turbochager
wastegate solenoid valve
AK200441
BATTERY
A
B
AD
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 "B" state Normal state
Connected Opened Negative
pressure leaks
Closed Negative
pressure
maintained
Disconnected Opened Negative
pressure
maintained
.
B Check of coil resistance
AK200442
1. Measure the resistance between the solenoid terminals.
Standard value: 29 −35 Ωat 20°C

ON-VEHICLE SERVICE
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INTAKE AND EXHAUST 15-9
NO.2 turbocharger wastegate solenoid or black
connector
.
A Operation check
AK703283 AC
No. 2 turbochager
wastegate solenoid
AK200441
BATTERY
A
B
AD
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 "B" state Normal state
Connected Opened Negative
pressure leaks
Closed Negative
pressure
maintained
Disconnected Opened Negative
pressure
maintained
.
B Check of coil resistance
AK200442
1. Measure the resistance between the solenoid terminals.
Standard value: 29 −35 Ωat 20°C
TURBOCHARGER BYPASS VALVE CHECK
M1151001600217
AK703106AD
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 65 kPa (19
in.Hg) and check operation of the valve. Also check that air
tightness is maintained.
Negative pressure Valve operation
Approximately 65 kPa (19
in.Hg)
Starts opening

AIR CLEANER
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INTAKE AND EXHAUST
15-10
AIR CLEANER
REMOVAL AND INSTALLATION M1151002101951
AC710665
2
1
5
13
14
15
7
12
11
17
AB
10
3
4
6
8
16
9.5 ± 3.5 N·m
84 ± 31 in-lb
9.5 ± 3.5 N·m
84 ± 31 in-lb
7.0 ± 3.0 N·m
62 ± 27 in-lb
4.0 ± 1.0 N·m
36 ± 8 in-lb
4.0 ± 1.0 N·m
36 ± 8 in-lb
1.5 ± 0.3 N·m
14 ± 2 in-lb
6.0 ± 1.0 N·m
53 ± 9 in-lb
8.5 ± 2.5 N·m
75 ± 22 in-lb
8.5 ± 2.5 N·m
75 ± 22 in-lb
9
N
Removal steps
1. Air cleaner intake duct
2. Air cleaner element
3. Air cleaner body
4. Air by-pass valve vacuum hose
connection
5. Air by-pass valve connection
6. Harness clamp connection
7. Mass airflow sensor connector
connection
8. Air cleaner cover assembly
>> A << 9. Mass airflow sensor
10. Air cleaner support
11. Gasket
12. Air cleaner cover
13. Breather hose connection
14. Vacuum hose connection
15. Air cleaner intake hose
16. Harness clamp connection
17. Air cleaner bracket
Removal steps (Continued)