INTAKE AND EXHAUST
CONTENTS
| SPECIFICATIONS | 2 |
|---|---|
| General Specifications | 2 |
| Service Specifications | 2 |
| SERVICE ADJUSTMENT PROCEDURES | З |
|
Turbocharger Supercharging Pressure
Inspection <4D56> |
Э |
|
Waste Gate Actuator Inspection
<4D56, 4M40> |
. 3 |
| Intake Manifold Vacuum Inspection | 3-1 |
|
Supercharging Pressure Control System
Inspection |
3-1 |
|
Supercharging Pressure Relief Solenoid Valve
Inspection |
3-1 |
| Variable Induction Control System Inspection <6G74> | 3-2 |
| Vacuum Tank Inspection | 3-2 |
| INTERCOOLER <4D56> | 4 |
| INTERCOOLER <4M40> | 5-1 |
| INTAKE MANIFOLD <6G74> | 5-3 |
| INTAKE MANIFOLD <6G72 - 24 VALVE> | 5-6 |
|
TURBOCHARGER AND EXHAUST MANIFOLD
<4D56> |
6 |
| TURBOCHARGER AND EXHAUST MANIFOLD <4M40> | 7-1 |
| EXHAUST MANIFOLD <4G64> | 8 |
| EXHAUST MANIFOLD <6G72 - 12 VALVE> | 9 |
| EXHAUST MANIFOLD <6G74> |
|
| EXHAUST MANIFOLD <6G72 - 24 VALVE> | 9-2 |
|
EXHAUST PIPE, MUFFLER AND CATALYTIC
CONVERTER <4G64, 6G72 - 12 VALVE> |
10 |
| EXHAUST PIPE AND MUFFLER <4D56> | 11 |
|
EXHAUST PIPE, MUFFLER AND CATALYTIC
CONVERTER <6G72 - 24 VALVE, 6G74> |
12 |
|
EXHAUST PIPE AND MUFFLER
<4M40> |
13 |
E1644
SPECIFICATIONS
GENERAL SPECIFICATIONS
| Items | Specifications |
|---|---|
| Air filter | |
| Туре | Dry type |
| Element | Unwoven cloth type |
| Exhaust system | |
| Front exhaust pipe | |
| <4G64, 6G72, 6G74> | Dual type |
| <4D56, 4M40> | Single type |
| Muffler | Expansion resonance type |
| Coupling | Spherical coupling and flat coupling |
| Suspension system | Rubber hangers and rubber suspenders |
| Turbocharger | |
| Туре | Exhaust gas turbine type |
| Identification No. | |
| <4D56> | TD04-11G-4 |
| <4M40> | TD04-12T-4 |
| Supercharging pressure control | Waste gate actuator |
| Intercooler | |
| Туре | Air cooled type |
SERVICE SPECIFICATIONS
| Items | Standard | Limit | |
|---|---|---|---|
| Intake and exhaust manifolds | |||
|
Distortion of cylinder head
contacting surface |
mm (in.) | Less than 0.15 (0.0059) | 0.3 (0.012) |
| Turbocharger | |||
| Initial starting pressure of waste gate actuator | kPa (kg∕cm², psi) | ||
| <4D56> | 82 (0.84, 12) | — | |
| <4M40> | 89 (0.91, 13) | _ |
E15CB--
SERVICE ADJUSTMENT PROCEDURES
TURBOCHARGER SUPERCHARGING PRESSURE INSPECTION <4D56>
Caution
The driving test should be carried out by two people at a place where fully-open acceleration can be done, and reading of the measurement values on the pressure gauge should be made by the person in the passenger seat.
- (1) Remove the hose that is connected to the fuel injection pump boost compensator, and install the pressure gauge via the T-joint, as shown in the illustration.
- (2) Accelerate the vehicle in second gear (M/T) or L range (A/T) with the throttle fully open, and take a reading of the measurement value on the pressure gauge when the engine speed reaches approximately 3,000 r/min.
-
(3) If the pressure is not positive pressure, the reason is probably one of the following, so carry out the following inspection.
- Waste gate actuator is defective
- Leaking turbo pressure
- Turbocharger is defective
-
(4) If the turbo pressure is 82 kPa (0.84 kg/cm2, 12 psi.), the reason is probably an abnormality in the turbo pressure control, so carry out the following inspection.
- Waste gate actuator rubber hose is disconnected or burst
- Waste gate actuator is defective
- Waste gate valve is defective
WASTE GATE ACTUATOR INSPECTION <4D56, 4M40>
- (1) Connect a hand pump (pressurization type) to the nipple.
- (2) While gradually increasing the pressure, check the pressure where the waste gate actuator rod begins to move [approx. 1mm (0.04 in.) stroke)]
Standard value: <4D56> <4M40>
82 kPa ( 89 kPa (
82 kPa (0.84 kg/cm2, 12 psi.) 89 kPa (0.91 kg/cm2, 13 psi.)
Caution
To prevent damage to the diaphragm, do not apply pressure more than 90 kPa (0.9 kg/cm2, 13 psi.) <4D56> or more than 115 kPa (1.17 kg/cm2, 17 psi.) <4M40>.
(3) If the value is widely outside the standard value, inspect the actuator or the waste gate valve, and replace if necessary.
15-3-1
INTAKE MANIFOLD VACUUM INSPECTION E15FBAB
Refer to GROUP 11 - Service Adjustment Procedures.
SUPERCHARGING PRESSURE CONTROL SYS-TEM INSPECTION <Vehicles with supercharging pressure relief solenoid valve>
- (1) Remove the vacuum hose (yellow) from the supercharging pressure relief solenoid valve and plug the hose.
- (2) Connect a hand vacuum pump to the supercharging pressure relief solenoid valve.
- (3) Check the vacuum condition.
| Engine condition | Normal condition |
|---|---|
| ldling | 0 mmHg |
| 2,000 r/min. | 300 mmHg (12 in.Hg) or more |
SUPERCHARGING PRESSURE RELIEF SOLENOID VALVE INSPECTION </br>Vehicles with supercharging<br/>pressure relief solenoid valve>OPERATION INSPECTION
- (1) Connect a hand vacuum pump to the solenoid valve nipple (a) (see the illustration to the left).
- (2) Using a jumper wire, connect between the solenoid valve terminal and battery terminal.
- (3) Connecting and disconnecting the jumper wire at the battery negative terminal to apply a negative pressure, check tightness.
| Jumper wire | nipple condition | Normal condition |
|---|---|---|
| Connected | Open | Negative pressure leaks. |
| Close | Negative pressure is held. | |
| Disconnected | Open | Negative pressure is held. |
© Mitsubishi Motors Corporation Dec. 1993
COIL RESISTANCE INSPECTION
Measure resistance between solenoid valve terminals.
Standard value: 36 – 44 [at 20°C (68°F)]
VARIABLE INDUCTION CONTROL SYSTEM IN-SPECTION <6G74>
- (1) Warm up the engine.
- (2) Connect a tachometer.
- (3) Use a three-way joint to connect a vacuum gauge between the variable induction control solenoid valve and the vacuum motor.
- (4) Start the engine, check to be sure that vacuum is applied to the vacuum gauge and check the following items.
| Engine revolution | Normal condition | Solenoid valve |
|---|---|---|
| 3200 r/min or less | Vacuum maintained | Closed |
| Race the engine suddenly at 3200 r/min or less | Vacuum does not change | Closed |
| 3400 r/min or more | Vacuum leaks | Open |
(5) Check to be sure that the rod of vacuum motor is operating during these checks.
VACUUM TANK INSPECTION
-
(1) Install a hand vacuum pump to port A and check to be sure that air-tightness is maintained when 503 mmHg of negative pressure is applied.
- After checking, remove the hand vacuum pump.
(2) Check to be sure that air passes through when port B is sucked, and that air does not pass through when port B is blown.
VARIABLE INDUCTION CONTROL SOLENOID VALVE INSPECTION OPERATION CHECK
- (1) Use a hand vacuum pump to apply vacuum to the vacuum tank (white vacuum hose connected) side nipple
- (2) Check air-tightness by applying voltage to the solenoid valve terminals.
| Battery voltage | The other nipple of the valve | Normal condition |
|---|---|---|
| Applied | Open | Vacuum leaks |
| Close with a finger | Vacuum maintained | |
| Not applied | Open | Vacuum maintained |
COIL CONTINUITY CHECK
Use an ohmmeter to measure the resistance.
Standard value: 36–44 Ω (at 20°C)
INTERCOOLER <4D56> REMOVAL AND INSTALLATION
INSPECTION
E15HCAC
- Check the intercooler fins for bending damage or foreign matter.
- Check the intercooler hoses for cracking, damage or wear.
CHECKING AIR TEMPERATURE SWITCH
- (1) Immerse the air temperature switch in the hot water shown in the figure.
- (2) When changine the water temperature, check for continuity between the terminals with the circuit tester.
| 50±5°C (122±9°F) or less | Continuity |
|---|---|
| 60±3°C (140±5°F) or more | No continuity |
INSPECTION
matter
15-5-2
- Check the intercooler fins for bending damage or foreign
- Check the intercooler hoses for cracking, damage or wear.
AIR TEMPERATURE SWITCH
- (1) Immerse the air temperature switch in the hot water shown in the figure.
- (2) When changine the water temperature, check for continuity between the terminals with the circuit tester.
| 50 ± 5°C or less | No continuity |
|---|---|
| 60 ± 3°C or more | Continuity |
SERVICE POINTS OF INSTALLATION
12.INSTALLATION OF BRANCH HOSE/11. BRANCH PIPE/10. AIR HOSE B/9. AIR HOSE A
Install the hose bands so that they are at the indicated positions.
INTAKE MANIFOLD <6G74>
REMOVAL AND INSTALLATION
INSPECTION
M15MCAN
Check the following points; replace the part if a problem is found.
- (1) Damage or cracking of any part.
- (2) Clogging of the negative pressure (vacuum) outlet port, or clogging of the water or gas passages.
SERVICE POINTS OF INSTALLATION 31. INSTALLATION OF INTAKE MANIFOLD GASKET
Install the gaskets so that the projections face in the directions shown in the illustration.
30. INSTALLATION OF INTAKE MANIFOLD / 29. CONE DISC SPRING
Tighten the intake manifold mounting nuts one bank after the other by the following procedure.
<For green cone disc spring>
- (1) Tighten the nuts in the right bank to 7 Nm (0.7 kgm, 5 ft.lbs.).
- (2) Tighten the nuts in the left bank to 20 to 23 Nm (2.0 to 2.3 kgm, 14 to 17 ft.lbs.)
- (3) Tighten the nuts in the right bank to 20 to 23 Nm (2.0 to 2.3 kgm, 14 to 17 ft.lbs.)
- (4) Repeat steps (2) and (3) one more time respectively.
<For black cone disc spring>
- (1) Tighten the nuts in the right bank to 3 to 5 Nm (0.3 to 0.5 kgm, 2.2 to 3.6 ft.lbs.).
- (2) Tighten the nuts in the left bank to 12 to 15 Nm (1.2 to 1.5 kgm, 9 to 11 ft.lbs.).
- (3) Tighten the nuts in the right bank to 12 to 15 Nm (1.2 to 1.5 kgm, 9 to 11 ft.lbs.).
- (4) Repeat steps (2) and (3) one more time respectively.
23. INSTALLATION OF HIGH-PRESSURE FUEL HOSE
(1) Apply a little amount of new engine oil to the O-ring. Caution
Be sure to prevent the engine oil from entering into the delivery pipe.
(2) Insert the hose, being careful not to damage the Oring, and tighten securely.
21. INSTALLATION OF AIR INTAKE PLENUM GASKET
Install with gasket protrusions in the position illustrated.
© Mitsubishi Motors Corporation Jun. 1994
INTAKE MANIFOLD <6G72 – 24 VALVE>
REMOVAL AND INSTALLATION
15-5-7 INTAKE AND EXHAUST – Intake Manifold <6G72 – 24 VALVE>
INSPECTION
M15MCAN
Check the following points: replace the part if a problem is found.
- (1) Damage or cracking of any part.
- (2) Clogging of the negative pressure (vacuum) outlet port, or clogging of the water or gas passages.
SERVICE POINTS OF INSTALLATION 10. INSTALLATION OF INTAKE MANIFOLD GASKET
Install the gaskets so that the projections face in the directions shown in the illustration.
9. INSTALLATION OF INTAKE MANIFOLD / 8. CONE DISC SPRING
Tighten the intake manifold mounting nuts one bank after the other by the following procedure.
- (1) Tighten the nuts in the right bank to 7 Nm (0.7 kgm, 5 ft.lbs.).
- (2) Tighten the nuts in the left bank to 20 to 23 Nm (2.0 to 2.3 kgm, 14 to 17 ft.lbs.).
- (3) Tighten the nuts in the right bank to 20 to 23 Nm (2.0 to 2.3 kgm, 14 to 17 ft.lbs.)
- (4) Repeat steps (2) and (3) one more time respectively.
2. INSTALLATION OF HIGH-PRESSURE FUEL HOSE
(1) Apply a little amount of new engine oil to the O-ring.
Be sure to prevent the engine oil from entering into the delivery pipe.
(2) Insert the hose, being careful not to damage the O-ring, and tighten securely.
TURBOCHARGER AND EXHAUST MANIFOLD <4D56> REMOVAL AND INSTALLATION
E15LBAD
© Mitsubishi Motors Corporation Dec. 1993
INSPECTION TURBOCHARGER ASSEMBLY CHECK
E15LCAF
- Visually check the turbine wheel and the compressor wheel for cracking or other damage.
- Check whether the turbine wheel and the compressor wheel can be easily turned by hand.
- Check for oil leakage from the turbocharger assembly.
- Check whether or not the waste gate valve remains open. If any problem is found, replace the part after disassembly.
OIL PIPE AND OIL-RETURN PIPE CHECK
Check the oil pipe and oil-return pipe for clogging, bending, or other damage.
If there is clogging, clean it.
EXHAUST MANIFOLD CHECK
• Damage or cracking of any part.
(1) Clean the alignment surfaces shown in the illustration.
(2) Supply clean engine oil from the oil pipe mounting hole of the turbocharger assembly.
Caution
When cleaning, take care that no foreign material gets into the engine coolant or oil passages hole.
© Mitsubishi Motors Corporation July 1993
PWJE9086-D
TURBOCHARGER AND EXHAUST MANIFOLD <4M40>
REMOVAL AND INSTALLATION
INSPECTION TURBOCHARGER ASSEMBLY CHECK
- Visually check the turbine wheel and the compressor wheel for cracking or other damage.
- Check whether the turbine wheel and the compressor wheel can be easily turned by hand.
- Check for oil leakage from the turbocharger assembly.
- Check whether or not the waste gate valve remains open. If any problem is found, replace the part after disassembly.
OIL PIPE AND OIL-RETURN PIPE CHECK
Check the oil pipe and oil-return pipe for clogging, bending or other damage. If there is clogging, clean it.
EXHAUST MANIFOLD CHECK
• Damage or cracking of any part.
21. INSTALLATION OF TURBOCHARGER ASSEMBLY
- (1) Clean the alignment surfaces shown in the illustration.
- (2) Supply clean engine oil from the oil pipe mounting hole of the turbocharger assembly.
Caution
When cleaning, take care that no foreign material gets into the engine coolant or oil passages hole.
© Mitsubishi Motors Corporation Dec. 1993
PWJE9086-E
FXHAUST MANIFOLD <4G64>
REMOVAL AND INSTALLATION
Removal steps
- 1. Exhaust manifold cover
- 2. Gasket
- Oxygen sensor Exhaust maniofld
- 5. Exhaust manifold gasket
INSPECTION EXHAUST MANIFOLE
• Damage or cracking of any part.
PWJE9086
E15NA-1
EXHAUST MANIFOLD <6G72 - 12 VALVE>
INSPECTION EXHAUST MANIFOLD
E15NCAE2
XHAUSI MANIFULD
• Damage or cracking of any part.
EXHAUST MANIFOLD <6G74>
REMOVAL AND INSTALLATION
• Damage or cracking of any part.
5. Exhaust manifold gasket
EXHAUST MANIFOLD <6G72 – 24 VALVE>
REMOVAL AND INSTALLATION
.......................................
INSPECTION EXHAUST MANIFOLD
• Damage or cracking of any part.
EXHAUST PIPE, MUFFLER AND CATALYTIC CONVERTER <4G64. 6G72 - 12 VALVE>
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Oneration Removal and installation of the under cover
Removal steps
- 1. Tail pipe
- 2. Gasket
- 3. Hanger bracket
- 4. Hanger
- 5. Main muffler
- 6. Hanger
- 7. Center exhaust pipe 8. Suspender
- 9. Gasket
- 10. Catalytic converter
- 11. Oxygen sensor
- 12. Front exhaust pipe (L.H.) ) <6G72>
- 13. Gasket 14. Front exhaust pipe (R.H.)
- 15. Gasket
- 16. Front exhaust pipe }<4G64>
- 17. Gasket 18. Heat protector
-
19. Front panel heat protector 20. Rear heater heat protector
- <Vehicles with rear heater>
INSPECTION
- E15RCAI
- Check the mufflers and pipes for corrosion or damage.
- Check the rubber hangers and rubber suspenders for deterioration or damage.
- Check for gas leakage from mufflers and pipes.
© Mitsubishi Motors Corporation Jun. 1994
PWJE9086-F
EXHAUST PIPE AND MUFFLER <4D56>
REMOVAL AND INSTALLATION
E15RA---
INSPECTION
PWJE908
E15RCAI
- Check the mufflers and pipes for corrosion or damage.
- Check the rubber hangers and rubber suspenders for deterioration or damage.
- Check for gas leakage from mufflers and pipes.
© Mitsubishi Motors Corporation Feb. 1991
EXHAUST PIPE, MUFFLER AND CATALYTIC CONVERTER <6G72 – 24 VALVE, 6G74>
REMOVAL AND INSTALLATION
INSPECTION
- Check the mufflers and pipes for corrosion or damage.
- Check the rubber hangers and rubber suspenders for deterioration or damage.
- Check for gas leakage from mufflers and pipes.
EXHAUST PIPE AND MUFFLER <4M40>
INSPECTION
E15RCAI
- Check the mufflers and pipes for corrosion or damage.
- Check the rubber hangers and rubber suspenders for deterioration or damage.
- Check for gas leakage from mufflers and pipes.
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