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)

AIR CLEANER
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INTAKE AND EXHAUST 15-11
INSTALLATION SERVICE POINT
.
>>A<< MASS AIRFLOW SENSOR INSTALLATION
CAUTION
Do not over-tighten. If the mass airflow sensor installation
screw is over-tightened, the air cleaner support thread
may be damaged.

INTAKE MANIFOLD
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INTAKE AND EXHAUST
15-12
INTAKE MANIFOLD
REMOVAL AND INSTALLATION M1151003002723
Pre-removal operation
•Engine Upper Cover Removal (Refer to GROUP 16, Igni-
tion System −Ignition Coil P.16-39).
•Air By-pass Valve, Air By-pass Hose, Charge Air Cooler
Intake Hose B Removal (Refer to P.15-15).
•Air Cleaner Assembly Removal (Refer to P.15-10).
•Drive Belt Removal (Refer to GROUP 11A, Crankshaft
Pulley P.11A-21).
•Throttle Body Removal (Refer to GROUP 13A, Throttle
Body P.13A-918).
•Fuel Delivery Pipe and Fuel Injector Assembly Removal
(Refer to GROUP 13A, Injector P.13A-914).
Post-installation operation
•Fuel Delivery Pipe and Fuel Injector Assembly Installation
(Refer to GROUP 13A, Injector P.13A-914).
•Throttle Body Installation (Refer to GROUP 13A, Throttle
Body P.13A-918).
•Air Cleaner Assembly Installation (Refer to P.15-10).
•Drive Belt Installation (Refer to GROUP 11A, Crankshaft
Pulley P.11A-21).
•Air By-pass Valve, Air By-pass Hose, Charge Air Cooler
Intake Hose B Installation (Refer to P.15-15)
•Engine Upper Cover Installation (Refer to GROUP 16,
Ignition System −Ignition Coil P.16-39).
AC711118
5
3
2
6
18
15
1
19
N
10
17
20
8
13
12
N
9(Engine oil)
21
20
AC
20
23 ± 6 N·m
17 ± 4 ft-lb
10 ± 2 N·m
89 ± 17 in-lb
23 ± 6 N·m
17 ± 4 ft-lb
23 ± 6 N·m
17 ± 4 ft-lb
23 ± 6 N·m
17 ± 4 ft-lb
8.0 ± 2.0 N·m
71 ± 18 in-lb
9.5 ± 2.5 N·m
35 ± 22 in-lb
5.0 ± 1.0 N·m
44 ± 9 in-lb
10 ± 2 N·m
89 ± 17 in-lb
10 ± 2 N·m
89 ± 17 in-lb
14 ± 1 N·m
120 ± 13 in-lb
10 ± 2 N·m
89 ± 17 in-lb
7
14
23 ± 6 N·m
17 ± 4 ft-lb
16
N
11
N
(Engine oil)
4
Removal steps
1. Rocker cover PCV hose
2. Emission control equipment
vacuum hose connection
3. Emission vacuum hose connection
4. Brake booster vacuum hose
connection
Removal steps (Continued)

INTAKE MANIFOLD
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INTAKE AND EXHAUST 15-13
Required Special Tool:
•MB992188: Fuel Injection Pipe Wrench
REMOVAL SERVICE POINT
.
<<A>> NO.2 INTAKE AIR TEMPERATURE SEN-
SOR REMOVAL
AC707100
MB992188
AC
No.2 Intake air temperature sensor
Use special tool MB992188 to remove the No.2 intake air tem-
perature sensor.
INSTALLATION SERVICE POINTS
.
>>A<< NO.2 INTAKE AIR TEMPERATURE SEN-
SOR INSTALLATION
AC707100
MB992188
AC
No.2 Intake air temperature sensor
Tighten the No.2 intake air temperature sensor to the specified
torque by using special tool MB992188.
Tightening torque: 14 ±1 N⋅m (120 ±13 in-lb)
.
5. Control wiring harness connection
6. Engine oil level gauge
7. O-ring
>> B << 8. Manifold absolute pressure sensor
>> B << 9. O-ring
<< A >> >> A << 10. No.2 Intake air temperature sensor
11. Gasket
12. Vacuum hose connection
13. Purge control solenoid valve
14. Starter wiring harness clamp
15. Intake manifold stay (front)
16. Starter wiring harness clamp
17. Intake manifold stay (rear)
18. Intake manifold
19. Intake manifold gasket
20. Harness bracket
21. Engine upper cover bracket (front)
Removal steps (Continued)

INTAKE MANIFOLD
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INTAKE AND EXHAUST
15-14
>>B<< O-RING/MANIFOLD ABSOLUTE
PRESSURE SENSOR INSTALLATION
CAUTION
•Install the manifold absolute pressure sensor, taking
care that no shock is applied to it.
•Do not use a manifold absolute pressure sensor that
has been dropped.
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.
INSPECTION M1151003101170
.
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.

CHARGE AIR COOLER
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INTAKE AND EXHAUST 15-15
CHARGE AIR COOLER
REMOVAL AND INSTALLATION M1151002400410
AC709089
1
AB
2
3
4
5
6
7
8
9
10
11
14
12
13
13
6.0 ± 1.0 N·m
54 ± 8 in-lb
20 ± 5 N·m
15 ± 3 ft-lb
9.5 ± 3.5 N·m
85 ± 30 in-lb
6.0 ± 1.0 N·m
54 ± 8 in-lb
6.0 ± 1.0 N·m
54 ± 8 in-lb 6.0 ± 1.0 N·m
54 ± 8 in-lb
6.0 ± 1.0 N·m
54 ± 8 in-lb
9.5 ± 3.5 N·m
85 ± 30 in-lb
6.0 ± 1.0 N·m
54 ± 8 in-lb
9.5 ± 3.5 N·m
85 ± 30 in-lb
6.0 ± 1.0 N·m
54 ± 8 in-lb
6.0 ± 1.0 N·m
54 ± 8 in-lb
6.0 ± 1.0 N·m
54 ± 8 in-lb
9.5 ± 3.5 N·m
85 ± 30 in-lb
Removal steps
1. Turbocharger by-pass valve
vacuum hose connection
2. Turbocharger by-pass valve
3. Charge air cooler intake hose A
4. Charge air cooler intake pipe A
5. Charge air cooler intake hose B
•Air cleaner body (Refer to P.15-10)
6. Turbocharger by-pass valve hose
7. Charge air cooler outlet hose E
•Headlight support panel cover
(Refer to GROUP 51, Front
Bumper and Radiator Grille
Assembly P.51-16 )
8. Charge air cooler intake pipe B
9. Charge air cooler intake hose D
•Front bumper and radiator grille
assembly (Refer to GROUP 51,
Front Bumper and Radiator Grille
Assembly P.51-16 )
10. Charge air cooler outlet pipe C
11. Charge air cooler outlet hose C
12. Charge air cooler hanger bracket
(LH)
13. Charge air cooler hanger
14. Charge air cooler assembly
Removal steps (Continued)

EXHAUST MANIFOLD AND TURBOCHARGER
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INTAKE AND EXHAUST
15-16
EXHAUST MANIFOLD AND TURBOCHARGER
REMOVAL AND INSTALLATION M1151008900576
Pre-removal operation
•Engine Room Under Cover Front A, B, Engine Room
Under Cover Center and Engine Room Side Cover (RH)
Removal (Refer to GROUP 51, Under Cover P.51-16).
•Engine Coolant Draining (Refer to GROUP 14, On-vehicle
Service −Engine Coolant Replacement P.14-17).
•Engine Oil Draining (Refer to GROUP 12, On-vehicle Ser-
vice −Engine Oil Replacement P.12-5).
•Engine Upper Cover Removal (Refer to GROUP 16, Igni-
tion System −Ignition Coil P.16-39).
•Charge Air Cooler Intake Hose A and Charge Air Cooler
Intake Pipe A Removal (Refer to P.15-15).
•Air Cleaner Assembly and Air Cleaner Intake Hose
Removal (Refer to P.15-10).
•Front Exhaust Pipe Removal (Refer to P.15-24).
•Strut Tower Bar Removal (Refer to GROUP 42A, Strut
Tower Bar P.42A-15).
•Cowl Top Panel Removal (Refer to GROUP 42A, Loose
Panel P.42A-15).
Post-installation operation
•Cowl Top Panel Installation (Refer to GROUP 42A, Loose
Panel P.42A-15).
•Strut Tower Bar Installation (Refer to GROUP 42A, Strut
Tower Bar P.42A-15).
•Front Exhaust Pipe Installation (Refer to P.15-24).
•Charge Air Cooler Intake Hose A and Charge Air Cooler
Intake Pipe A Installation (Refer to P.15-15).
•Air Cleaner Assembly and Air Cleaner Intake Hose Instal-
lation (Refer to P.15-10).
•Engine Oil Refilling (Refer to GROUP 12, On-vehicle Ser-
vice −Engine Oil Replacement P.12-5).
•Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
Service −Engine Coolant Replacement P.14-17).
•Engine Upper Cover Removal (Refer to GROUP 16, Igni-
tion System −Ignition Coil P.16-39).
•Engine Room Under Cover Front A, B, Engine Room
Under Cover Center and Engine Room Side Cover (RH)
Removal (Refer to GROUP 51, Under Cover P.51-16).

AC710567AB
10 ± 2 N·m
89 ± 17 in-lb
31
N
10 ± 2 N·m
89 ± 17 in-lb
7.0 ± 3.0 N·m
62 ± 26 in-lb
29 ± 2 N·m
22 ± 1 ft-lb to +65˚ ± 5˚
10 ± 2 N·m
89 ± 17 in-lb
25 ± 4 N·m
19 ± 2 ft-lb
51 ± 7 N·m
38 ± 5 ft-lb
64 ± 5 N·m
48 ± 3 ft-lb
49 ± 5 N·m
37 ± 3 ft-lb
51 ± 7 N·m
38 ± 5 ft-lb
64 ± 5 N·m
48 ± 3 ft-lb
25 ± 4 N·m
19 ± 2 ft-lb
9.5 ± 2.5 N·m
85 ± 22 in-lb 9.0 ± 1.0 N·m
80 ± 8 in-lb
17 ± 2 N·m
13 ± 1 ft-lb
25 ± 4 N·m
19 ± 3 ft-lb
51 ± 7 N·m
38 ± 5 ft-lb
64 ± 5 N·m
48 ± 3 ft-lb
28 ± 1 N·m
21 ± 1 ft-lb
9.5 ± 1.5 N·m
85 ± 13 in-lb
42 ± 7 N·m
31 ± 5 ft-lb
10 ± 2 N·m
89 ± 17 in-lb
5.0 ± 2.0 N·m
45 ± 17 in-lb 5.0 ± 2.0 N·m
45 ± 17 in-lb
8.5 ± 1.5 N·m
76 ± 13 in-lb
25 ± 4 N·m
19 ± 2 ft-lb
1
2
3
4
5
N
6
7
8
N
9
10
11
N
12
13
14
16
15
17
18 22
23
N
19
20
21 24
25
26
N
27
28
N
(Engine oil)
29 29
30
32
33
34
N
12 ± 1 N·m
107 ± 8 in-lb
EXHAUST MANIFOLD AND TURBOCHARGER
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INTAKE AND EXHAUST 15-17
Removal steps
1. Dash panel heat protector
2. Exhaust manifold cover
3. Emission vacuum control hose
connection
4. Turbocharger air outlet fitting
Removal steps (Continued)

EXHAUST MANIFOLD AND TURBOCHARGER
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INTAKE AND EXHAUST
15-18
5. Turbocharger air outlet fitting
gasket
<<A>> >> F << 6. Turbocharger compressor
bracket
7. Turbocharger air inlet fitting
8. Turbocharger air inlet fitting
gasket
9. Turbocharger water feed hose
10. Turbocharger water feed pipe
11. Gasket
12. Turbocharger water return hose
>> E << 13. Turbocharger exhaust outlet
fitting bracket
14. Transfer heat protector
15. Drive shaft heat protector
16. Steering gear and linkage heat
protector
17. Turbocharger protector A
18. Turbocharger protector B
19. Emission vacuum control hose
connection
20. Turbocharger pin
<< B >> 21. Waste gate actuator
22. Turbocharger exhaust outlet
fitting
23. Turbocharger exhaust outlet
fitting gasket
>> C << 24. Turbocharger bracket and
turbocharger assembly coupling
bolt
25. Turbocharger oil feed tube
connection
26. Gasket
27. Turbocharger oil return tube
connection
28. O-ring
>> D << 29. Exhaust manifold and
turbocharger assembly coupling
bolt and nut
30. Exhaust manifold
31. Exhaust manifold gasket
32. Turbocharger gasket
33. Turbocharger assembly
•Transfer assembly (Refer to
GROUP 22A, Transfer Assembly
P.22A-125 <M/T>), (Refer to
GROUP 22C, Transfer Assembly
P.22C-339 <TC-SST>)
>> C << 34. Turbocharger bracket
Removal steps (Continued)

AC710615
31 ± 2 N·m
23 ± 1 ft-lb
9.5 ± 2.5 N·m
85 ± 22 in-lb
35
36
37
38
39
40
41
N
N
N
AB
9.0 ± 1.0 N·m
80 ± 8 in-lb
42 ± 7 N·m
31 ± 5 ft-lb
Removal steps
<< C >> 35. Turbocharger oil feed tube
36. Gasket
37. Turbocharger oil return tube
>> B << 38. Turbocharger oil return tube
gasket
39. Turbocharger water return pipe
40. Gasket
>> A << 41. Turbocharger
EXHAUST MANIFOLD AND TURBOCHARGER
TSB Revision
INTAKE AND EXHAUST 15-19
Required Special Tools:
•MB992274: Palm Socket
•MB991614: Angle Gauge
Removal steps (Continued)

EXHAUST MANIFOLD AND TURBOCHARGER
TSB Revision
INTAKE AND EXHAUST
15-20
REMOVAL SERVICE POINTS
.
<<A>> TURBOCHARGER COMPRESSOR
BRACKET REMOVAL
AC710947AC
MB992274
Turbocharger
compressor
bracket
Turbocharger
air inlet fitting
Use special MB992274 to remove the turbocharger compres-
sor bracket mounting bolt (cylinder block side).
.
<<B>> WASTE GATE ACTUATOR REMOVAL
AC710816AB
Adjusting rod
Lock nut
CAUTION
Never loosen the locking nuts and adjusting rod of the
waste gate actuator.
.
<<C>> TURBOCHARGER OIL FEED TUBE
REMOVAL
CAUTION
Take care not to allow foreign objects to get into the oil
passage hole of the turbocharger assembly after the turbo-
charger oil feed tube is removed.
INSTALLATION SERVICE POINTS
.
>>A<< TURBOCHARGER INSTALLATION
1. Clean the turbocharger oil feed tube, turbocharger water
feed pipe and turbocharger water return 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.
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.
.