15 intake and exhaust.pdfmitsu

8/12/2019 15 Intake and Exhaust.pdfmitsu

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INTAKE AND EXHAUST

Click on the applicable bookmark to selected the required model year


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INTAKE AND EXHAUST Service Specifications/Sealant/On-vehicle Service15-2

SERVICE SPECIFICATIONS 15100030128

Items Standard value Limit

Waste gate actuator activation pressure kPa Approx. 83

Intake air temperature switch C OFF (no continuity) 55 or less

ON (continuity) 57 or more

Manifold distortion of the installation surface mm 0.15 or less 0.20

SEALANT 15100050025

Item Specified sealant Remark

Water outlet fitting MITSUBISHI GENUINE PARTMD970389 or equivalent

Semi-drying sealant

ON-VEHICLE SERVICE 15100180137

INTAKE MANIFOLD VACUUM CHECK

Refer to GROUP 11A On-vehicle Service

TURBOCHARGER SUPERCHARGING CHECK 15100100041

CautionConduct the driving test in a location where driving atfull acceleration can be done with safety. Two personshould be in the vehicle when the test is conducted; theperson in the passenger seat should read the indicationsshown by the pressure meter.

1. Remove the boost compensator hose from the fuelinjection pump, and install a pressure gauge as shownin the illustration.

2. Drive at full-throttle acceleration in second gear and thenmeasure the supercharging when the engine speed inabout 3,000 r/min.

3. When the indicated supercharging does not becomepositive pressure, check the following items. Malfunction of the waste gate actuator. Leakage of supercharging pressure. Malfunction of the turbocharger.

4. When the indicated supercharging is 84 kPa or more,supercharging control may be faulty, therefore check thefollowings. Disconnection or cracks of the waste gate actuator

rubber hose. Malfunction of the waste gate actuator. Malfunction of the waste gate valve.


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INTAKE AND EXHAUST On-vehicle Service 15-3

WASTE GATE ACTUATOR CHECK 15100120023

1. Connect a manual pump (pressure-application type) tonipple.

2. While gradually applying pressure, check the pressurethat begins to activate (approx. 1 mm stroke) the wastegate actuator rod.

Standard value: Approx. 83 kPa

CautionIn order to avoid damage to the diaphragm, do notapply a pressure of 91 kPa or higher.

3. If there is a significant deviation from the standard value,check the actuator or the waste gate valve: replace ifnecessary.

POWER RELAY CHECK 15100620011

INTERCOOLER FAN MOTOR RELAY CONTINUITY CHECK

Battery voltage Terminal No.

1 3 4 5

Power is not supplied

Power is supplied


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INTAKE AND EXHAUST Air Cleaner15-4

AIR CLEANER 15100210058

REMOVAL AND INSTALLATION

4 Nm

4 Nm

8

9 Nm

4 Nm

9 Nm

9 Nm 4 Nm

9 Nm

76

2

1

43

5 9

9 Nm

9 Nm

8

76

2

1

49

5

Removal steps

1. Breather hose connection2. Air intake hose3. Resonator 4. Resonator5. Air duct

6. Air flow sensor assembly7. Air cleaner cover8. Air cleaner element9. Air cleaner body


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INTAKE AND EXHAUST Air Cleaner 15-5

9 Nm

9 Nm

8

9 Nm

2.0 Nm

4 Nm

7 6

3

4

9 Nm

9 Nm

9 Nm

4 Nm 4 Nm

4 Nm

4 Nm

4 Nm

4 Nm

2.0 Nm

2

19

8 7 65

2

319

5

Removal steps

1. Air intake hose A2. Breather hose connection3. Air intake hose B4. Resonator 5. Air cleaner cover

6. Bolt7. Air cleaner element8. Air cleaner body9. Air cleaner bracket


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INTAKE AND EXHAUST Intercooler and Intercooler Fan-ECU15-6

INTERCOOLER AND INTERCOOLER FAN-ECU 15100420031


9 Nm

9 Nm

3

2

1

6

9

8

8

7

4

5

9 Nm

9 Nm

Intercooler fan-ECU removal steps

1. Scuff plate2. Cowl side trim3. Intercooler fan-ECU

Intercooler removal steps

4. Intake air temperature switchconnector

5. Intercooler fan motor connector6. Air hose B connection (Intake

manifold side)7. Air hose A-2 connection (Turbochar-

ger side)8. Front bracket9. Intercooler and bracket assembly


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INTAKE AND EXHAUST Intercooler and Intercooler Fan-ECU 15-7

DISASSEMBLY AND REASSEMBLY 15100660013

9 Nm

6 Nm

6 Nm

1

5

2

98

7

10

46

3

9 Nm

Disassembly steps1. Air hose A-22. Blanch tube3. Blanch tube bracket4. Intercooler cover5. Air hose A-1

6. Air hose B7. Intake air temperature switch8. Intercooler bracket9. Fan and motor assembly

10. Intercooler

INSPECTION 15100430027

Check the intercooler fins for bending damage or foreignmatter.

Check the intercooler hoses for cracking, damage or wear.


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INTAKE AND EXHAUST Intercooler and Intercooler Fan-ECU15-8

INTAKE AIR TEMPERATURE SWITCH CHECK15100630014

1. Immerse the intake air temperature switch in the hot watershown in the figure.

2. When changing the water temperature, check forcontinuity between the terminals with the circuit tester.

Standard value:Temperature Continuity

Less than 55 C(Temperature at point A)

OFF (No continuity)

More than 57 C(Temperature at point B)

ON (Continuity)

ON

OFF

Watertemperature

B

A


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INTAKE AND EXHAUST Intake Manifold 15-9

INTAKE MANIFOLD 15100300274


Pre-removal Operation Fuel Discharge Prevention

(Refer to GROUP 13A On-vehicle Service) Engine Coolant Draining

Air Cleaner Removal (Refer to P. 15-4.) Battery and Battery Tray Removal

Post -installation Operation Engine Coolant Supplying Battery and Battery Tray Installation Air Cleaner Installation (Refer to P.15-4.)

20 Nm

14 Nm

O-ring

Sealant:MITSUBISHIGENUINE PARTMD970389 orequivalent

Engine Oil5 Nm

12 Nm

20 Nm

22 Nm

64

1

8

6

2

3

7

5

13

10

4

11

12

3)

9

Removal steps

1. Throttle body (Refer to GROUP13A Throttle Body.)

2. PCV hose3. Brake booster vacuum hose

connection4. Water outlet fitting5. Vacuum hose connection

A 6. High-pressure fuel hose connection

7. Fuel return hose connection8. Injector connector

A 9. Injector and delivery pipe assembly10. EGR valve11. Intake manifold stay12. Intake manifold13. Intake manifold gasket


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INTAKE AND EXHAUST Intake Manifold 15-10

REMOVAL SERVICE POINT

A DELIVERY PIPE AND INJECTOR REMOVAL

Remove the delivery pipe (with the injectors and pressureregulator attached to it).

CautionCare must be taken, when removing the delivery pipe,

not to drop the injector.

INSTALLATION SERVICE POINT

A HIGH-PRESSURE FUEL HOSE INSTALLATION

1. When connecting the high-pressure fuel hose to thedelivery pipe, apply a small amount of new engine oilto the O-ring and then insert the high-pressure fuel hose,being careful not to damage the O-ring.

Caution

Be careful not to let any engine oil get into the deliverypipe.


Check the following points; replace the part if a problem isfound.

INTAKE MANIFOLD CHECK

1. Check for damage or cracking of any part.2. Check for obstruction of the negative pressure (vacuum)

outlet port, and for obstruction of the water passage orgas passage.

3. Using a straight edge and thickness gauge, check fordistortion of the cylinder head installation surface.

Standard value: 0.15 mm or less

Limit: 0.20 mm

Fuel high-pressure hose

Delivery pipe

O-ring


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INTAKE AND EXHAUST Intake and ExhaustManifold 15-11

INTAKE AND EXHAUST MANIFOLD 15100360029


Pre-removal and Post-installation Operation Front Exhaust Pipe Removal and Installation

(Refer to P.15-19.)

2

12 15 Nm

18 Nm

1

3

4

5

18 Nm

18 Nm

18 Nm

Removal steps

1. Vacuum pipe attaching bolt2. Intake manifold3. Heat protector4. Exhaust manifold

5. Intake and exhaust manifold gasket



INTAKE AND EXHAUST MANIFOLD CHECK

1. Check for damage or cracking of any part.2. Using a straight edge and thickness gauge, check for

distortion of the cylinder head installation surface.

Standard valve: 0.15 mm or less

Limit: 0.20 mm


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INTAKE AND EXHAUST Turbocharger and ExhaustManifold 15-12

TURBOCHARGER AND EXHAUST MANIFOLD 15100450023


Pre-removal and Post-installation Operation Engine Coolant Draining and Supplying Air Cleaner Cover and Air Intake Hose Removal and

Installation (Refer to P. 15-4.)

Intercooler Removal and Installation (Refer to P. 15-6.) Brake Master Cylinder Heat Protector Removal and

Installation

43 Nm

9 Nm

6

18 Nm

19 Nm

9 Nm

17 Nm

42 Nm

30 Nm

4

2

5 10

12

11

7

1

3

9

18 Nm

9 Nm

18 Nm

8

Removal steps

1. Front exhaust pipe connection2. Boost hose3. Waste gate actuator4. Heat protector A5. Heat protector6. Intake manifold7. Water pipe B

8. Water pipe A9. Oil pipe

10. Oil return hose connection11. Exhaust manifold and turbocharger

assembly12. Intake and exhaust manifold gasket


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60 Nm

14

9 Nm

60 Nm

12 15 Nm

19

16

18

13

1720

15

13. Exhaust fitting14. Exhaust fitting gasket15. Oil-return pipe16. Oil-return pipe gasket17. Exhaust manifold18. Turbocharger gasket

A 19. Turbocharger assembly20. Heat protector


A TURBOCHARGER ASSEMBLY INSTALLATION

1. Clean the alignment surfaces shown in the illustration.2. Supply clean engine oil from the oil pipe mounting hole

of the turbocharger assembly.

CautionWhen cleaning, take care that no foreign material getsinto the engine coolant or oil passages hole.


TURBOCHARGER ASSEMBLY CHECK

Visually check the turbine wheel and the compressorwheel for cracking or other damage.

Check whether the turbine wheel and the compressorwheel 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.Compressorwheel


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OIL PIPE AND OIL RETURN PIPE CHECK 15100650010

Check the oil pipe and oil return pipe for clogging, bending,or other damage. If there is clogging, clean it.

EXHAUST MANIFOLD CHECK 15100340108

Damage or cracking of any part.


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INTAKE AND EXHAUST Turbocharger 15-15

TURBOCHARGER 15100600015

DISASSEMBLY AND REASSEMBLY

2

5 Nm

6

5

4

3

1

Disassembly steps

E 1. CouplingD 2. Turbine housing

A C 3. Snap ringB B 4. Turbine wheel assembly

5. Compressor coverA 6. O-ring

DISASSEMBLY SERVICE POINTS

A SNAP RING REMOVAL

Lay the unit with the compressor cover side facing downand using snap ring pliers, remove the compressor coverattaching snap ring.

CautionWhen removing the snap ring, hold it with fingers toprevent it from springing away.

Snap ring


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INTAKE AND EXHAUST Turbocharger15-16

B TURBINE WHEEL ASSEMBLY REMOVAL

Remove the turbine wheel assembly, striking thecircumference of the compressor cover with a plastic hammer.The turbine wheel assembly may be a little hard to removedue to an O-ring put on the outer circumference.

CLEANING

(1) Use a clean cleaning oil commercially available. Do notuse corrosive cleaning oils as they could damage to someparts.

(2) Use a plastic scraper or hard brush to clean aluminumparts.

REASSEMBLY SERVICE POINTS

A O-RING INSTALLATION

Apply a light coat of engine oil to a new O-ring and fit inthe turbine wheel assembly groove.

CautionWhen installing the O-ring, use care not to damage it.A damaged O-ring causes oil leaks.

B TURBINE WHEEL ASSEMBLY

1. Apply a light coat of engine oil to the periphery of theO-ring.

2. Install the turbine wheel assembly to the compressor coverin relation to the dowel pin.

CautionUse care not to damage the blades of turbine wheeland compressor wheel.

C SNAP RING INSTALLATION

Lay the assembly with the compressor cover facing downand fit the snap ring.

CautionFit the snap ring with its chamfered side facing up.

Turbinewheel as-sembly

O-ring

Dowel pin hole

Dowel pin

Snap ringChamferededge

Turbine wheelassembly

Compressorcover


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INTAKE AND EXHAUST Turbocharger 15-17

D TURBINE HOUSING INSTALLATION

Install the turbine housing in relation to the dowel pin.

CautionUse care not to damage the blades of turbine wheel.

E COUPLING INSTALLATION

Install the coupling and tighten to specified torque.


TURBINE HOUSING

1. Check the housing for traces of contact with the turbinewheel, cracks due to overheating, pitching, deformationand other damage. Replace with a new turbine housingif cracked.

2. Operate the waste gate valve lever manually to checkthat the gate can be operated and closed smoothly.

COMPRESSOR COVER

Check the compressor cover for traces of contact with thecompressor wheel and other damage.

TURBINE WHEEL ASSEMBLY

1. Check the turbine and compressor wheel blades for bend,burr, damage, corrosion and traces of contact on theback side and replace if defective.

2. Check the oil passage of the turbine wheel assemblyfor deposit and clogging.

3. In the case of water cooled type, check also the waterpassage for deposit and clogging.

4. Check the turbine wheel and compressor wheel for lightand smooth turning.

OIL PIPE/OIL RETURN PIPE

Correct or replace the oil pipe and oil return pipe if clogged,collapsed, deformed or otherwise damaged.

Dower pin hole

Dower pin

Coupling

Traces forcontact

Compressor

wheel

Oil passage

Turbine wheel

Water passage


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INTAKE AND EXHAUST Exhaust Manifold 15-18

EXHAUST MANIFOLD 15100330327


Pre-removal and Post-installation Operation Front Exhaust Pipe Removal and Installation (Refer

to P. 15-19.) Air Cleaner Removal and Installation (Refer to P.

15-4.)

14 Nm

1

Exhaust Manifold mounting bolt tightening torque

: 29 Nm

: 49 Nm2

3

4

3

Removal steps

1. Heat protector2. Engine hanger3. Exhaust manifold4. Exhaust manifold gasket



EXHAUST MANIFOLD CHECK

1. Check for damage or cracking of any part.2. Using a straight edge and a thickness gauge, check for

distortion of the cylinder head installation surface.

Standard value: 0.15 mm or less

Limit: 0.20 mm


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INTAKE AND EXHAUST Exhaust Pipe and Main Muffler 15-19

EXHAUST PIPE AND MAIN MUFFLER 15100540249


Pre-removal and Post-installation Operation Front Under Cover Removal and Installation Front Under Cover and Transfer Case Protector

Removal and Installation

35 Nm

25 Nm

18

50 Nm

44 Nm

50 Nm

13 Nm25 Nm

12

16

10 13

11 87

2

4 3

5

3

6

1

78

9

17

1514

13 Nm

3, 7, 14

Main muffler removal steps

1. Bolt2. Main muffler3. Hanger4. Heat protector5. Hanger bracket6. Rear body floor heat protector


1. Bolt7. Hanger8. Heat protector9. Center exhaust pipe

10. Nut11. Catalytic converter12. Front floor heat protector B

Front exhaust pipe removal steps

10. Nut13. Oxygen sensor14. Hanger15. Heat protector16. Exhaust support bracket17. Front exhaust pipe18. Front floor heat protector A


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INTAKE AND EXHAUST Exhaust Pipe and Main Muffler15-20

25 Nm

17

50 Nm

48 Nm

13 Nm

11 35

34

2

110

91630 Nm

25 Nm

1117

1314

15

16 910

76

125 Nm6

7

12

44 Nm

50 Nm

3, 6, 13

6

25 Nm

25 Nm

8

13 Nm


1. Bolt2. Main muffler3. Hanger4. Heat protector

5. Hanger bracket

Center exhaust pipe removal steps

1. Bolt6. Hanger7. Heat protector8. Center exhaust pipe9. Bolt or nut

10. Catalytic converter11. Front floor heat protector B


9. Bolt or nut 12. Oxygen sensor13. Hanger14. Heat protector

15. Exhaust support bracket16. Front exhaust pipe17. Front floor heat protector A


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15-1

INTAKE ANDEXHAUST

CONTENTS

GENERAL 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Outline of Changes 2. . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL TOOL 2. . . . . . . . . . . . . . . . . . . .

SERVICE SPECIFICATIONS 2. . . . . . . . . . . . . . . . .

ON-VEHICLE SERVICE 3. . . . . . . . . . . . . . . . . . . . .

Turbocharger Supercharging Pressure Check 3. . .

Supercharging Pressure Control SystemCheck 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Variable Geometry Actuator Check 5. . . . . . . . . . . .

Variable Geometry Solenoid Valve Check 5. . . . . .

Waste Gate Actuator Check 6. . . . . . . . . . . . . . . . . .

AIR CLEANER 6. . . . . . . . . . . . .

INTERCOOLER 6. . . . . . . . . . . .

INTAKE AND EXHAUST MANIFOLD ANDTURBOCHARGER 7. . . . . . . . .

EXHAUST PIPE AND MAIN MUFFLER 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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INTAKE AND EXHAUST General/Special Tool /Service Specifications15-2

GENERAL

OUTLINE OF CHANGES

With the modification below by additional emission regulation step IIIcompatible 4D56 engine, the serviceprocedure of the part that is different from previous service procedure has been established.As the VG (Variable Geometry) turbocharger cannot be disassembled, the service procedure for the VGturbocharger is not described.

The turbocharger and intercooler have been added to the vehicle with 2WD. The turbocharger of the vehicle with 4WD has been modified to VG (Variable Geometry) turbocharger.

With additional oxygen sensor by compatible emission regulation step III, the service procedure of 4G64engine that is different from previous service procedure has been established.

NOTEFor description of structure and operation of VG (Variable Geometry) turbocharger, refer to 02 MY PAJEROWorkshop Manual.

SPECIAL TOOL

Tool Number Name Use

MD998770 Oxygen sensorwrench

Removal/Installation of oxygen sensor

SERVICE SPECIFICATIONS

Items Standard Value

Variable geometry actuator activation vacuum

(Approximately 1 mm stroke) kPa

Approximately 10.5 12.5

Waste gate actuator activation pressure(Approximately 1 mm stroke) kPa

Approximately 92

Variable geometry solenoid valve coil resistance(at 20C)

29 35


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ON-VEHICLE SERVICE

TURBOCHARGER SUPERCHARGINGPRESSURE CHECK

CautionConduct the driving test in a location where driving atfull acceleration can be done with safety. Two personshould be in the vehicle when the test is conducted; theperson in the passenger seat should read the indicationsshown by the MUT-II.

1. Set the vehicle to the pre-inspection condition.2. Turn the ignition switch to LOCK (OFF) position, and

connect the diagnosis connector to the MUT-II.3. Use the data list function named Item No. 04 boost

pressure sensor of the MUT-II to check the superchargingpressure when the engine speed increases to approximately3,000 r/min or more by driving at full acceleration in 2nd.

4. When the indicated supercharging pressure does notbecome positive pressure, check the following items.

Malfunction of the waste gate actuator

Malfunction of the boost pressure sensor Leakage of supercharging pressure Malfunction of the turbocharger

5. When the indicated supercharging pressure is 133 kPaor more or 84 kPa ormore , superchargingcontrol may be faulty, therefore check the followings. Disconnection or cracks of the waste gate actuator

rubber hose Malfunction of the variable geometry actuator

Malfunction of the waste gate actuator

Malfunction of the variable nozzle

Malfunction of the waste gate valve

Malfunction of the variable geometry solenoid valve

Malfunction of the boost pressure sensor Malfunction of the variable geometry control pressure

sensor

MUT-II


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INTAKE AND EXHAUST On-vehicle Service15-4

SUPERCHARGING PRESSURE CONTROLSYSTEM CHECK

1. Set the vehicle to the pre-inspection condition.2. Turn the ignition switch to LOCK (OFF) position, and

connect the diagnosis connector to the MUT-II.3. Start the engine, and let it run at idle.4. Select the actuator testing function named Item No. 35

or No. 36of the MUT-IIto check that the variable geometryactuator vacuum and the supercharging pressure increasewhen the variable geometry solenoid valve is activated.

Variable geometrysolenoid valvecondition

Variable geometryactuator vacuum

Superchargingpressure

OFF 0 kPa Approximately 1kPa

ON Approximately 80kPa

Approximately 3kPa

NOTE(1) If the variable geometry actuator vacuum is not in a normal

condition, the variable geometry actuator, variablegeometry solenoid valve, variable geometry controlpressure sensor, vacuum pump or hose may be faulty.

(2) If the variable geometry actuator vacuum is in a normalcondition but the supercharging pressure is not in a normalcondition, the variable geometry turbocharger nozzle,boost pressure sensor, or hose may be faulty.

CautionBe careful not to forcibly activate the variable geometrysolenoid valve to the fullest degree when running at ahigh speed. Too much supercharging pressure coulddamage the engine or the turbocharger.

MUT-II


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VARIABLE GEOMETRY ACTUATOR CHECK

1. Connect the hand vacuum pump to nipple.2. While gradually applying vacuum, check the vacuum that

begins to active (approximately 1 mm stroke) the variablegeometry actuator rod.

Standard value: Approximately 10.5 12.5 kPaCautionIn order to avoid damage to the diaphragm, do not apply avacuum of 59 kPa or higher.

3. If there is a significant deviation from the standard value,check the actuator or the variable nozzle: replace ifnecessary.

VARIABLE GEOMETRY SOLENOID VALVECHECK

NOTEWhen disconnecting the vacuum hose, always make a markso that it can be reconnected at original position.

1. Disconnect the vacuum hose (black, red stripe) from thesolenoid valve.

2. Disconnect the harness connector.3. Connect a hand vacuum pump to the nipple to which

the red striped vacuum hose was connected.4. Check airtightness by applying a vacuum with voltage

applied directly from the battery to the variable geometrysolenoid valve and without applying voltage.

Battery voltage Nipple condition Normal condition

Applied Both nipples areopened.

Vacuum leaks.

Nipple A is closed. Vacuum is maintained.

Not applied Both nipples areopened.

Vacuum leaks.

Nipple C is closed. Vacuum is maintained.

5. Measure the resistance between the terminals of thesolenoid valve.

Standard value: 29 35 (at 20C)

Variable geometryactuator

Battery

B

C

A


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INTAKE AND EXHAUST On-vehicle Service/Air Cleaner /Intercooler 15-6

WASTE GATE ACTUATOR CHECK

1. Connect a manual pump (pressure-application type) tonipple.

2. While gradually applying pressure, check the pressurethat begins to activate (approx. 1 mm stroke) the wastegate actuator rod.

Standard value: Approximately 92 kPa

CautionIn order to avoid damage to the diaphragm, do notapply a pressure of 105 kPa or higher.

3. If there is a significant deviation from the standard value,check the actuator or the waste gate valve: replace ifnecessary.

AIR CLEANER

With additional turbocharger of the vehicle with 2WD, the air cleaner is modified to the air cleaner ofthe vehicle with 4WD. The service procedure is same as one of the vehicle with 4WD.

INTERCOOLER

With additional air temperature sensor by adopting electronic-controlled injection pump, the air temperatureswitch of the intercooler is not adopted. The service procedure is same as previous service procedureexcept for the air temperature sensor.On new models, the engine-ECU controls the intercooler fan. Due to this change, the intercooler fan-ECUhas been discontinued.

Waste gateactuator


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INTAKE AND EXHAUST Intake and Exhaust Manifold andTurbocharger 15-7

INTAKE AND EXHAUST MANIFOLD AND TURBOCHARGER


Pre-removal and Post-installation Operation Intercooler Removal and Installation (Refer to P.15-6.) Air Cleaner Cover and Air Intake Hose Removal and

Installation (Refer to P.15-6.)

EGR Valve and EGR Cooler Removal and Installation(Refer to GROUP 17.)

18 2 Nm

6

42

5

10

12

11

7

1

3

9

8

4

24 4 Nm

14 1 Nm

18 2 Nm

13

18 2 Nm

14

9.0 1.0 Nm

42

7 Nm

17 2 Nm

20 4 Nm

9.0 1.0 Nm

18 2 Nm

14 1 Nm

42 7 Nm

11 1 Nm

1615

1718

19

20

21

22

23

24

12 1 Nm49 10 Nm

25

26

2728

29

30

16


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Removal steps

1. Brake master cylinder heatprotector

2. Air temperature sensor connector3. Throttle solenoid valve connector4. Vacuum hose connection5. Throttle valve solenoid assembly6. Air temperature sensor7. Gasket8. Air intake fitting9. Gasket

10. Throttle body assembly11. Gasket12. Earth cable connection13. Engine hanger14. Turbocharger heat protector15. Water pipe A and water hose

assembly

16. Gasket17. Oil pipe assembly18. Gasket19. Intake manifold20. Exhaust manifold heat protector21. Water pipe B connection22. Gasket23. Boost hose24. Waste gate actuator25. Front exhaust pipe connection26. Gasket27. Oil return hose connection28. Exhaust manifold and turbocharger

assembly29. Intake and exhaust manifold gasket30. Oil return hose

32

33

3537

34 36

31

38

59 10 Nm

59 10 Nm 14 1 Nm

9.0 1.0 Nm

31. Exhaust fitting32. Exhaust fitting gasket33. Heat protector34. Oil return pipe

35. Oil return pipe gasket36. Exhaust manifold37. Turbocharger gasket

A 38. Turbocharger assembly


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6

4

2

10

1211

13

8

24 4 Nm14 1 Nm

18 2 Nm

18

18 2 Nm

149.0 1.0 Nm

17 2 Nm

20 4 Nm

18 2 Nm

14 1 Nm42 7 Nm

14 1 Nm

15

16

17

19

22

21

25

23

24

12 1 Nm

49 10 Nm

26

27

29

28

18 2 Nm

31

30

5

79

5.0 1.0 Nm

13

14 1 Nm

20

11 1 Nm

32

33

35

34

9.0 1.0 Nm

Removal steps

1. Brake master cylinder heatprotector

2. Air temperature sensor connector3. Throttle solenoid valve connector4. VGT solenoid valve connector

5. Vacuum hose connection6. Solenoid valve assembly7. VG control pressure sensor

connector8. Vacuum hose connection9. VG control pressure sensor

10. Air temperature sensor11. Gasket12. Air intake fitting13. Gasket14. Throttle body assembly15. Gasket16. Earth cable connection17. Engine hanger18. Turbocharger upper heat protector

19. Oil pipe assembly20. Gasket21. Vacuum hose connection22. Intake manifold23. Exhaust manifold heat protector

24. Water pipe A and water hoseassembly25. Gasket26. Water pipe B connection27. Gasket28. VG actuator29. Turbocharger lower heat protector30. Front exhaust pipe connection31. Gasket32. Oil return hose connection33. Exhaust manifold and turbocharger

assembly34. Intake and exhaust manifold gasket35. Oil return hose


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37

38

39

36

40

59 10 Nm

9.0 1.0 Nm

36. Oil return pipe37. Oil return pipe gasket38. Exhaust manifold

39. Turbocharger gasketA 40. Turbocharger assembly


A TURBOCHARGER ASSEMBLY INSTALLATION

1. Clean the alignment surfaces shown in the illustration.2. Supply clean engine oil from the oil pipe mounting hole

of the turbocharger assembly.

CautionWhen cleaning, take care that no foreign material getsinto the engine coolant or oil passages hole.


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INTAKE AND EXHAUST Exhaust Pipe and Main Muffler 15-11

EXHAUST PIPE AND MAIN MUFFLER


Pre-removal and Post-installation Operation Front Under Cover Removal and Installation Front Under Cover and Transfer Case Protector

Removal and Installation

5

9

1112

13

10

8 6

2

1

4

7

2, 6, 11

32

67

12 2 Nm

49 10 Nm

24 4 Nm

59 9 Nm

49 9 Nm

24 5 Nm

44 5 Nm

44

5 Nm


1. Main muffler2. Hanger3. Heat protector

Center exhaust pipe removal steps

4. Center exhaust pipeA A 5. Oxygen sensor

6. Hanger7. Heat protector8. Catalytic converter


A A 9. Oxygen sensor10. Front exhaust pipe11. Hanger12. Heat protector13. Exhaust support bracket

REMOVAL SERVICE POINT

A OXYGEN SENSOR REMOVAL

Use special tool to remove the oxygen sensor.


A OXYGEN SENSOR INSTALLATION

Use special tool to install the oxygen sensor.

MD998770

Oxygen sensor


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NOTES

15 intake and exhaust.pdfmitsu

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