GROUP 15 INTAKE AND EXHAUST

SPECIFICATIONS ............................................................................. 15-2

STRUCTURE AND OPERATION

1. Air Cleaner ................................................................................... 15-2
2. Turbocharger ................................................................................ 15-3

TROUBLESHOOTING ...................................................................... 15-5

ON-VEHICLE INSPECTION AND ADJUSTMENT

1.Measuring Turbo Boost Pressure .................................................. 15-6

AIR DUCT AND AIR CLEANER ....................................................... 15-8

TURBOCHARGER .......................................................................... 15-12

INTERCOOLER .............................................................................. 15-16

INTAKE MANIFOLD ........................................................................ 15-18

EXHAUST MANIFOLD .................................................................... 15-19

EXHAUST PIPE AND MUFFLER ................................................... 15-20

15-1
SPECIFICATIONS / STRUCTURE AND OPERATION
SPECIFICATIONS
/

Item Specifications
Air cleaner element type Filter paper type
Type TF035
Turbocharger
Manufacturer Mitsubishi Heavy Industries, Ltd.
Intercooler type Tube and corrugated fin air cooled type

STRUCTURE AND OPERATION

1. Air Cleaner
• The air cleaner is a single element
type.
• When the engine slows down below
the predetermined speed, the level of
vacuum in the air cleaner changes and
causes the unloader valve to vibrate.
Vibration of the unloader valve allows
the air cleaner to automatically dis-
charge any water and dust that has
accumulated inside.

15-2
 15
2. Turbocharger

2.1 Waste gate mechanism

• The waste gate mechanism allows ex-
cess exhaust gas to escape from the
turbocharger by means of an actuator
in order to maintain the boost pressure
at an appropriate level. This prevents
overrunning of the turbocharger and
excessive pressure buildups in the in-
take manifold.
• The boost pressure is led via a rubber
hose from the compressor cover to
chamber A in the actuator. When the
boost pressure in chamber A is less
than the predetermined value, the ac-
tuator does not function and the waste
gate valve remains closed. All exhaust
gas then flows toward the turbine
wheel.

15-3
STRUCTURE AND OPERATION
• When the boost pressure in chamber
A exceeds the predetermined value,
the waste gate valve opens, reducing
the amount of exhaust gas flowing to-
ward the turbine wheel. As a result,
the speed of the compressor wheel,
and thus the boost pressure, are re-
duced.

15-4
TROUBLESHOOTING 15
Symptoms

Intake and exhaust system vibrates and/

Engine output is insufficient
Oil consumption is too high

or makes abnormal noises

Engine is difficult to start
Reference Gr

Exhaust gas is white

Exhaust gas is black
Possible causes
Air cleaner Clogged air cleaner element O O O
Defective bearings O O O
Carbon deposits on shaft and turbine wheel O O
Interference between shaft and turbine wheel as-
O O O
sembly and turbine back plate
Interference between shaft and turbine wheel as-
O O O
sembly and turbine housing
Bent shaft and turbine wheel O O O
Cartridge assembly

Broken shaft and turbine wheel O O O

Interference between compressor wheel and com-
O O O
pressor cover
Turbocharger
Seizure of thrust sleeve and/or thrust bearing O O O
Broken compressor wheel O O O
Oil leakage due to worn piston ring and/or inserts O O O
Poorly installed piston rings O
Faulty sliding inside each part due to clogged lubri-
O O
cating oil pipe and eyebolt
Damage to each oil seal due to clogged oil return
O O
pipe
Poorly installed compressor cover O O O O
Poorly installed turbine housing O O
Intercooler Foreign substance adheres to front core of intercooler O
Butterfly valve does not open O O O
Throttle actuator Gr13E
Faulty operation of butterfly valve O O O
Deformed front pipe, Muffler, and/or tail pipe O
Poorly installed front pipe, Muffler, and/or tail pipe O
Inappropriate valve clearance O
Defective cylinder head gasket O
Worn valve and valve seat and/or carbon deposits O
Gr11
Weakened valve springs O
Worn and/or damaged piston rings O O
Worn and/or damaged piston ring grooves O O
Malfunctioning cooling system O Gr14
Excessive engine oil level O Gr12
Seizure of main moving parts O Gr11
Uneven or excessive fuel injection O Gr13E

15-5
ON-VEHICLE INSPECTION AND ADJUSTMENT
1. Measuring Turbo Boost Pressure

Service standards
Location Maintenance item Standard value Limit Remedy
47 kPa
Boost pressure Measurement using Boost
– {350 mmHg}
(temperature of 20 °C, Pressure Gauge
– /3700 rpm Inspect or adjust
atmospheric pressure of
100 kPa {760 mmHg}) Measurement using Multi- 148 kPa
–
Use Tester (See Gr13E.) /3700 rpm

Special tools
Mark Tool name and shape Part No. Application

Boost pressure gauge MH061366 Measurement of turbo boost pressure

• Clean or replace the air cleaner element before measuring the

turbo boost pressure.
• Disconnect the vacuum hose on the boost pressure sensor side,
and attach to it.
• Warm up the engine sufficiently and then measure the boost pressure
at no-load maximum speed. At the same time, measure the engine
speed and atmospheric temperature.

15-6
 15
• Adjust the boost pressure to the standard value (boost pressure
changes according to the atmospheric temperature and the en-
gine speed).

[Atmospheric temperature correction of boost pressure]

• Based on the current atmospheric temperature, determine the
appropriate boost pressure correction coefficient in the graph.

[Engine speed correction of boost pressure]

• Subtract the median of the no-load maximum speed values from
the engine speed at the time of boost pressure measurement.
Use the difference to determine the necessary boost pressure
correction value (Pa) in the graph.
Median: 3700 rpm

[Calculation of corrected boost pressure]

• With P as the measured boost pressure, determine the correct-
ed boost pressure Pb using the following equation:
Pb = KtP + Pa
Pb: Corrected boost pressure
P: Measured boost pressure
Kt: Ambient temperature correction coefficient for boost pres-
sure
Pa: Boost pressure correction value
• The turbocharger must be inspected and/or adjusted if Pb is be-
low the specified limit.

15-7
AIR DUCT AND AIR CLEANER

Disassembly sequence
1 Connector 6 Air cleaner cap
2 Air inlet duct 7 Air cleaner element
3 Air hose 8 Air box
4 Air duct 9 Air cleaner case
5 Air duct

Assembly sequence
Follow the disassembly sequence in reverse.

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Clamp 3.0 to 3.4 {0.3 to 0.35} –

15-8
 15
Cleaning procedure
Cleaning: Filter element
• Blow a jet of compressed air at a pressure not higher than 685
kPa {7 kgf/cm2} against the inside surfaces of the element.
• Move the compressed air jet up and down along all pleats of the
filter paper element.

CAUTION
• Do not strike the element or hit it against another object to
remove dust.
• Do not blow compressed air against outside surfaces of the
element.

Inspection procedure
Inspection: Element
• Shine some electric light inside the element.
• Replace the element if thin spots or broken parts are evident in
the filter paper, or if the packing at the top of the element is dam-
aged.
Also replace the element if the dust on the element is damp with
oily smoke or soot, regardless of the replacement schedule.

Installation procedure
Installation: Air cleaner cap
: Alignment mark

15-9
AIR DUCT AND AIR CLEANER
Installation: Air duct
• The protruding portion of the connector is put between clamps.
• Installation is such that the space between the connector and
the air cleaner case measures the amount shown in the figure.

Installation: Air duct

Align the arrow marks “ ” on air duct and push it in until it hits
stopper.

Installation: Air hose

Align the arrow marks “ ” on air hose and push it in until it hits
stopper.

15-10
 15
M E M O

15-11
TURBOCHARGER
Removal sequence
1 Turbocharger coupler insulator
2 Front pipe
3 Turbocharger coupler
4 Gasket
5 Turbocharger insulator B
6 Turbocharger insulator A
7 Eyebolt
8 Water pipe
9 Eyebolt
10 Water pipe
11 Oil return pipe
12 Gasket
13 Eyebolt
14 Oil pipe
15 Turbocharger (See later sec-
tions.)
16 Gasket

*a: Exhaust manifold

Non-reusable parts

Installation sequence
Follow the removal sequence in reverse.

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Nut (turbocharger coupler mounting) 49 {5.0} –
Nut (front pipe mounting) 25 to 30 {2.5 to 3.1} –
Bolt (oil return pipe mounting)
20 {2.0} –
Eyebolt (oil pipe mounting)
Eyebolt (water pipe mounting) 25 {2.6} –
Bolt (turbocharger mounting) 54 {5.5} –

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Pouring into turbocharger Engine oil As required

Installation procedure
Installation: Turbocharger
• When installing the turbocharger, pour an appropriate amount of
engine oil from the oil port so that each part operates smoothly.

15-12
 15
Turbocharger
Disassembly sequence
1 Hose
2 Actuator
3 Coupling
4 Turbine housing
5 Snap ring
6 Compressor cover
7 O-ring
8 Cartridge assembly

: Non-reusable parts

Assembly sequence
Follow the disassembly sequence in re-
verse.
CAUTION
• The cartridge assembly cannot be
disassembled. If the turbine wheel
or the compressor cover is dam-
aged or does not rotate smoothly,
replace the entire cartridge assem-
bly.

Service standards (Unit: mm)

Location Maintenance item Standard value Limit Remedy
Play in axial directions 0.03 to 0.10 0.11 Replace
Cartridge
8 Play in radial Turbine wheel end 0.40 to 0.53 0.58 Replace
assembly
directions Compressor wheel end 0.55 to 0.66 0.72 Replace

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Bolt (coupling fastening) 8.3 {0.85} Wet

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Bolt threads MOLYKOTE BR-2 Plus As required
O-ring Engine oil As required

Work before removal

Mating marks
• Draw a line across the coupling, turbine housing, compressor
cover, and cartridge assembly. This line will serve as mating
marks in the installation procedure.

15-13
TURBOCHARGER
Removal procedure
Removal: Turbine housing
CAUTION
• Tap all around the end of the turbine housing with a rubber
hammer or a similar tool, being careful not damage the tur-
bine housing.
• Do not let the blades of the cartridge assembly hit the tur-
bine housing, as they are easily bent.

Removal: Compressor cover

CAUTION
• Tap all around the end of the turbine housing with a rubber
hammer or a similar tool, being careful not damage the tur-
bine housing.
• Do not let the blades of the cartridge assembly hit the tur-
bine housing, as they are easily bent.

Work after disassembly

Cleaning
• Before cleaning the parts, carry out a visual inspection for any
marks of burns or wear that may become difficult to find after the
cleaning. If any defects are evident, replace the part(s).
• Immerse the disassembled parts in an inflammable solvent Dai-
cleaner-T-30 by Daido Chemical Industry Co., Ltd.). Remove the
parts from the solvent, and dry them with compressed air.
If there is any solid matter remaining on the parts, remove them
with a plastic scraper or a bristle brush.
• Reimmerse the parts in the solvent.
• Dry each part with compressed air.
Inspection procedure
Inspection: Cartridge assembly
(1) Play in axial directions
• If the measurement exceeds the specified limit, replace the car-
tridge assembly.

15-14
 15
(2) Play in radial directions
• If the measurement exceeds the specified limit, replace the car-
tridge assembly.

Installation procedure
Installation: Snap ring
• Fit the snap ring into the compressor cover with the tapered sur-
face on top.
CAUTION
• Always keep one hand on the snap ring to prevent it from
flying off.

Work after installation

Inspection: Rotation of cartridge assembly
• Turn both wheels of the cartridge assembly to check that they
rotate smoothly.
• If anything abnormal is found, disassemble the cartridge assem-
bly and perform necessary service.

15-15
INTERCOOLER

Disassembly sequence
1 Air inlet hose 4 Air inlet hose
*a: Air inlet fitting
2 Air inlet hose 5 Intake temperature sensor *b: Turbocharger coupler
3 Air inlet pipe 6 Intercooler

Assembly sequence
Follow the disassembly sequence in reverse.

Service standards
Location Maintenance item Standard value Limit Remedy
Intercooler air leakage
8 (air pressure: 150 kPa {1.5 kgf/cm2} 0 cm3 {0 mL} – Replace
maintained for 30 seconds)

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Clamp 3.9 to 4.9 {0.4 to 0.5} –
Intake temperature sensor 12.7 to 16.7 {1.3 to 1.7} –

15-16
 15
Inspection procedure
Inspection: Intercooler
• Plug one of the air ports on the intercooler and connect an air
source to the other port. Place the intercooler in a tank of water
and apply air pressure at the specified level 150 kPa {1.5 kgf/
cm2} to the intercooler and retain pressure for 30 seconds.
• Replace the intercooler if any air leakage is evident.

Installation: Air inlet hose

• Install the air inlet hose so that its white paint faces the boss of
the air inlet pipe.
• Install the air inlet hose to the intercooler, air inlet pipe and turbo-
charger coupler to the dimensions as shown in the illustration.

• Install the air inlet hose to the intercooler and air inlet pipe to the
dimensions as shown in the illustration.

15-17
INTAKE MANIFOLD

Disassembly sequence
1 Vacuum hose 5 Gasket *a Cylinder head
2 Gas filter 6 Intake manifold : Non-reusable parts
3 Boost pressure sensor 7 Gasket
4 Intake fitting

Assembly sequence
Follow the disassembly sequence in reverse.

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Bolt (boost pressure sensor mounting) 4 to 6 {0.4 to 0.6} –
Gas filter 14.7 to 19.6 {1.5 to 2.0} –

Installation procedure
Installation: Gasket
• Install the gasket on the cylinder head in the illustrated direction.

15-18
EXHAUST MANIFOLD 15
Disassembly sequence
1 Insulator
2 EGR pipe
3 Gasket
4 Exhaust manifold
5 Gasket

: Non-reusable parts

Assembly sequence
Follow the disassembly sequence in re-
verse.

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Bolt (EGR pipe mounting) 30 {3.1} –
Nut (exhaust manifold mounting) 23.2 {2.4} –

Installation procedure
Installation: Gasket
• Install the gasket on the cylinder head in the illustrated direction.

15-19
EXHAUST PIPE AND MUFFLER
Disassembly sequence
1 Tail pipe
2 Gasket
3 Gasket
4 Front pipe
5 Exhaust brake unit (See Gr35)
6 Front pipe
7 Muffler

*a Exhaust manifold

Assembly sequence
Follow the disassembly sequence in re-
verse.

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Nut (tail pipe mounting)
26 to 33 {2.7 to 3.2} –
Nut (muffler mounting)
Nut (front pipe mounting) 25 to 30 {2.5 to 3.0} –
Bolt (exhaust brake unit mounting) 27 {2.7} –

Installation procedure
Installation: Front pipe
• Install the front pipe so that the amounts of offset in both vertical
and horizontal directions between the pipes in front of and be-
hind the bellows are smaller than the dimension indicated in the
illustration.
CAUTION
• The function of the bellows on the front pipe is to reduce
the vehicle noise level. It is not intended for compensating
for misalignment that may result from improper installation
of the front pipe. Install the front pipe properly to avoid ex-
cessive tension or other stress on the bellows.

15-20