INTAKE AND EXHAUST GROUP CONTENTS INTERCOOLER GENERAL INFORMATION SERVICE SPECIFICATIONS

Transcription

1 15-1 GROUP 15 ITAKE AD EXHAUST COTETS GEERAL IFORMATIO SERVICE SPECIFICATIOS SPECIAL TOOL O-VEHICLE SERVICE ITERCOOLER WATER SPRAY RELAY CHECK TURBOCHARGER SUPERCHARGIG PRESSURE CHECK SUPERCHARGIG PRESSURE COTROL SYSTEM CHECK WASTE GATE ACTUATOR CHECK WASTE GATE SOLEOID VALVE CHECK 15-4 AIR BY-PASS VALVE CHECK ILET MAIFOLD VACUUM CHECK AIR CLEAER REMOVAL AD ISTALLATIO ITERCOOLER REMOVAL AD ISTALLATIO ITERCOOLER WATER SPRAY REMOVAL AD ISTALLATIO ISPECTIO ILET MAIFOLD REMOVAL AD ISTALLATIO ISPECTIO EXHAUST MAIFOLD AD TURBOCHARGER REMOVAL AD ISTALLATIO ISPECTIO EXHAUST PIPE AD MAI MUFFLER REMOVAL AD ISTALLATIO

2 15-2 SUPERCHARGIG PRESSURE COTROL By controlling the duty of the waste gate solenoid valve, the waste gate actuator functions to control the supercharging pressure. This allows a supercharged pressure matching the engine operation state to be attained. Control is carried out to prevent excessive supercharging and thereby prevent engine damage. ITAKE AD EXHAUST GEERAL IFORMATIO GEERAL IFORMATIO M SERVICE SPECIFICATIOS Item Standard value Limit Turbocharger supercharging pressure (waste gate solenoid valve not operating) kpa Initial activation pressure of waste gate actuator Approximately 0 (at the stroke of approximately 1 mm) kpa Waste gate solenoid valve coil resistance (at 20 C) Ω Initial activation pressure of air bypass valve kpa Approximately 59 Manifold distortion of the installation surface mm 0.15 or less 0.20 M SPECIAL TOOL Tool umber ame Use MD Oxygen sensor wrench Removal and installation of oxygen sensor M

3 ITERCOOLER WATER SPRAY RELAY CHECK M ! CAUTIO The top and bottom of the intercooler water spray relay are difficult to identify. The triangle mark on the relay surface should be uppermost. ITAKE AD EXHAUST 15-3 O-VEHICLE SERVICE O-VEHICLE SERVICE TURBOCHARGER SUPERCHARGIG PRESSURE CHECK M ! CAUTIO Two persons should be in the vehicle when the test is conducted; the person in the passenger seat should read the indications shown by the pressure meter. Plug J/B Vacuum terminal 1. Removal the intercooler water spray relay. 2. Use the jumper leads to connect intercooler water spray relay terminal 2 to the negative battery terminal and terminal 3 to the positive battery terminal. 3. Check the continuity between intercooler water spray relay connector terminals 1 and 4 while alternately connecting and disconnecting the jumper leads from the battery terminals. Jumper leads Connected Disconnected AC3778AB Relay side AC3779 AB Continuity between terminals 1 and 4 Less than 2 Ω Open circuit 4. If there is a malfunction, replace the intercooler water spray relay. Waste gate actuator AK AB 1. Disconnect the hose (black) from the vacuum terminal, and connect the plug to the hose. Connect a pressure gauge to the vacuum terminal nipple. 2. Drive at full-throttle acceleration in second gear and then measure the supercharging pressure when the engine speed in about 3,000 r/min. Standard value: kpa 3. If the supercharging pressure deviates from the standard value, check the following items for possible cause. Malfunction of the waste gate actuator Leakage of supercharging pressure Malfunction of the turbocharger 4. When the indicated supercharging is more than standard value, supercharging control may be faulty, therefore check the followings. Malfunction of the waste gate actuator Malfunction of waste gate valve Disconnection or cracks of the waste gate actuator rubber hose

4 15-4 ITAKE AD EXHAUST O-VEHICLE SERVICE SUPERCHARGIG PRESSURE COTROL SYSTEM CHECK Boost hose M Disconnect the hose (black) from the vacuum terminal, and connect a three-way joint between the hose and the vacuum terminal. 2. Connect a hand vacuum pump to the three-way joint. 3. Disconnect the hose from the turbocharger waste gate actuator control boost nipple and plug the nipple. 4. Applying a negative pressure with the hand vacuum pump, check tightness both when the hose end is closed and when it is open. Engine state Hose end ormal state Stop (Ignition switch: O) Idling (after warm-up) Vacuum terminal Waste gate actuator Opened Closed Three-way joint AK305236AB egative pressure leaks. egative pressure is maintained. egative pressure leaks. OTE: If this check indicates an abnormal condition, the turbocharger waste gate actuator, turbocharger waste gate solenoid or hose is broken. WASTE GATE ACTUATOR CHECK M ! CAUTIO In order to avoid damage to the diaphragm, do not apply a pressure of 117 kpa or higher. 2. While gradually applying pressure, check the pressure that begins to activate (approximately 1 mm stroke) the waste gate actuator rod. Standard value: Approximately 0 kpa 3. If there is a significant deviation from the standard value, check the actuator or the waste gate valve: replace actuator or turbocharger assembly if necessary. WASTE GATE SOLEOID VALVE CHECK M OPERATIO CHECK A B Battery AK200441AC 1. Connect a hand vacuum pump to the solenoid valve nipple A. 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 B nipple ormal condition condition Connected Opened egative pressure leaks. Closed egative pressure is held. Disconnected Opened egative pressure is held. AK Connect a manual pump (pressure-application type) to nipple.

5 ITAKE AD EXHAUST 15-5 O-VEHICLE SERVICE COIL RESISTACE CHECK AIR BY-PASS VALVE CHECK M AK Measure the resistance between solenoid valve terminals Standard value: Ω (at 20 C) AK Remove the air bypass valve. 2. Connect the hand vacuum pump to the nipple of the air bypass valve. 3. Apply a negative pressure of approximately 54 kpa, and check that air tightness is maintained. 4. Also check operation of the valve. Standard value: egative pressure Approximately 59 kpa Valve operation It starts opening ILET MAIFOLD VACUUM CHECK M Refer to GROUP 11A On-vehicle Service P.11A-13.

6 15-6 ITAKE AD EXHAUST AIR CLEAER REMOVAL AD ISTALLATIO AIR CLEAER M ! CAUTIO Parts marked by * are made of recycled-paper mixed plastic material, so observe the following precautions. 1. Avoid any shock or load to these parts when removing and installing them. 2. Engage the case hinges securely when assembling these parts. OTE: Parts marked by * are made of recycled-paper mixed plastic material. Dispose of according to state and local laws * 4.0 ± 1.0 m 3 7 8* 9.0 ± 1.0 m ± 1.0 m 4.0 ± 1.0 m 9.0 ± 1.0 m ± 1.0 m 9.0 ± 1.0 m 9.0 ± 1.0 m 9 Removal steps 1. Intake air duct 2. Battery 3. Air cleaner assembly 4. Airflow sensor assembly 5. Gasket 6. Air cleaner housing cover 7. Air cleaner element AC2412 AB Removal steps (Continued) 8. Air cleaner housing 9. Air cleaner bracket. Waste gate solenoid valve 11. Air pipe C, air by-pass hose and air by-pass valve 12. Vacuum hose connection 13. Air intake hose

7 ITAKE AD EXHAUST 15-7 ITERCOOLER REMOVAL AD ISTALLATIO ITERCOOLER M Pre-removal and Post-installation Operation Intake Air Duct and Air Cleaner Assembly Removal and Installation (Refer to P.15-6). 12 ± 1 m 6.0 ± 1.0 m 6.0 ± 1.0 m 6.0 ± 1.0 m 6.0 ± 1.0 m ± 1.0 m ± 1.0 m 6.0 ± 1.0 m 12 ± 1 m ± 1 m 6.0 ± 1.0 m 8 12 ± 1 m ± 1 m Removal steps 1. Vacuum hose connection 2. Air by-pass valve 3. Air by-pass hose 4. Air hose E 5. Air pipe C 6. Air hose D Under cover (Refer to GROUP 51, Front Bumper Assembly P.51-3). 7. Air hose A 6.0 ± 1.0 m 6.0 ± 1.0 m 9 AC2413 AB Removal steps (Continued) Front bumper assembly (Refer to GROUP 51, Front Bumper Assembly P.51-3). 8. Air pipe B 9. Bracket. Air hose C 11. Air pipe A 12. Air hose B 13. Intercooler assembly

8 15-8 ITAKE AD EXHAUST ITERCOOLER WATER SPRAY ITERCOOLER WATER SPRAY REMOVAL AD ISTALLATIO M <ITERCOOLER WATER SPRAY OZZLE, HOSE AD TAK> AC ± 2 m ± 2 m AC3699 Intercooler water spray nozzle/water hose removal steps 1. Intercooler water spray water hose connection Front bumper assembly (Refer to GROUP 51, Front Bumper Assembly P.51-3). >>A<< Tape (for installation of intercooler water spray water hose) 2. Clips AC3964 AB Intercooler water spray nozzle/water hose removal steps (Continued) >>A<< 3. Intercooler water spray water hose assembly 4. Intercooler water spray nozzle assembly (Upper) 5. Clips 6. Intercooler water spray water hose 7. Joint 8. Intercooler water spray nozzle (Upper)

9 <ITERCOOLER WATER SPRAY SWITCH> ITAKE AD EXHAUST 15-9 ITERCOOLER WATER SPRAY Intercooler water spray nozzle/water hose removal steps (Continued) 9. Intercooler water spray nozzle (Lower). Intercooler water spray water hoses 11. Three-way joints 12. Stop valves Tape (for clip installation) 13. Clips 14. Pads Intercooler water spray tank removal steps 1. Intercooler water spray water hose connection 15. Intercooler water spray motor connector 16. Intercooler water spray tank assembly 17. Intercooler water spray water hose 18. Stop valve 19. Intercooler water spray motor 20. Packing 21. Intercooler water spray tank bracket Intercooler water spray switch Floor console AC2416 AB

10 15- ITAKE AD EXHAUST ITERCOOLER WATER SPRAY ISTALLATIO SERVICE POIT >>A<< ITERCOOLER WATER SPRAY WATER HOSE ASSEMBLY/TAPE ISTALLATIO 255 ± 5 mm Tape Stop valve Clip Pad 20 ± 5 mm Three-way joint 50 ± 5 mm Tape 80 mm 70 ± 5 mm Pad Three-way joint 30 ± 5 mm Stop valve Tape 190 ± 5 mm Tape Clip Clip 180 ± 5 mm 25 ± 5 mm 1. After the intercooler water spray water hoses, the three-way joints and the stop valves are assembled, affix the pads, the clips and the tape to the intercooler water spray water hoses as shown. AC211929AC

11 ITAKE AD EXHAUST ITERCOOLER WATER SPRAY <Viewed from inside of front bumper assembly> Tape Tape A Tape Intercooler water spray water hose assembly Clip Clip View A Tape AC3773AB 2. Use the clips to install the intercooler water spray water hose assembly to the front bumper assembly. 3. Adhere the tapes as shown in the illustration to locate the intercooler water spray water hose assembly in position.

12 15-12 ITAKE AD EXHAUST ITERCOOLER WATER SPRAY ISPECTIO M Intercooler Water Spray Switch Check Intercooler Water Spray Motor Check 1. Check the intercooler water spray motor with the intercooler water spray tank attached after the tank is supplied with water AC3780 Switch position Tester connection Specified condition AUTO 2 5 Less than 2 ohms 2 3 Open Circuit eutral 2 5 Open Circuit 2 3 Open Circuit MA 2 5 Open Circuit 2 3 Less than 2 ohms AC Check that the water is supplied with strong pressure after energizing terminal o. 1 with battery voltage and earthing terminal o. 2.

13 ITAKE AD EXHAUST ILET MAIFOLD ILET MAIFOLD REMOVAL AD ISTALLATIO M Pre-removal Operation Fuel Discharge Prevention (Refer to GROUP 13A, On-vehicle Service P.13A-387). Under Cover Removal (Refer to GROUP 51, Front Bumper P.51-3). Engine Coolant Draining (Refer to GROUP 14, On-vehicle Service P.14-15). Intake Air Duct Removal (Refer to P.15-6). Strut Tower Bar Removal (Refer to GROUP 42, Strut Tower Bar P.42-9). Throttle Body Removal (Refer to GROUP 13A, Throttle Body P.13A-402). Crossmember Bar Removal (Refer to GROUP 32, Engine Roll Stopper, Centremember P.32-8). Front Exhaust Pipe Removal (Refer to P.15-19). Post-installation Operation Front Exhaust Pipe Installation (Refer to P.15-19). Crossmember Bar Installation (Refer to GROUP 32, Engine Roll Stopper, Centremember P.32-8). Throttle Body Installation (Refer to GROUP 13A, Throttle Body P.13A-402). Strut Tower Bar Installation (Refer to GROUP 42, Strut Tower Bar P.42-9). Intake Air Duct Installation (Refer to P.15-6). Engine Coolant Refilling (Refer to GROUP 14, On-vehicle Service P.14-15). Under Cover Installation (Refer to GROUP 51, Front Bumper P.51-3). Accelerator Cable Adjustment (Refer to GROUP 17, On-vehicle Service P.17-3) ± 0.5 m 5.0 ± 1.0 m 11 ± 1 m 7 (Engine oil) ± 1 m (Engine oil) Removal steps 1. Rocker cover centre cover 2. Control wiring harness connection 3. Vacuum hose connection 4. Vacuum hoses connection 5. Fuel return hose connection >>A<< 6. Fuel high-pressure hose connection >>A<< 7. O-ring <<A>> 8. Delivery pipe, fuel injector, fuel return pipe and fuel pressure regulator assembly AC3728 AB Removal steps (Continued) 9. Insulators. Insulators 11. Oil level gauge and guide assembly 12. O-ring 13. Brake booster vacuum hose connection 14. Purge hoses connection

14 15-14 ITAKE AD EXHAUST ILET MAIFOLD 20 ± 2 m ± 6 m ± 1.0 m 20 ± 2 m ± 1 m ± 1 m ± 1 m ± 6 m ± 4 m ± 2 m ± 3 m 11 ± 1 m AC3729AB Removal steps 15. Detonation sensor connector 16. Purge control solenoid valve 17. Vacuum hose 18. Fuel pressure solenoid valve 19. PCV hose Alternator (Refer to GROUP 16, Charging System Alternator Assembly P.16-12). 20. EGR solenoid valve connector 21. EGR solenoid valve, vacuum pipe and hose assembly 22. Inlet manifold stay 23. EGR valve 24. EGR valve gasket 25. Earth cable connection 26. Crank angle sensor connector 27. Alternator brace stay 28. Inlet manifold 29. Inlet manifold gasket REMOVAL SERVICE POIT <<A>> DELIVERY PIPE, FUEL IJECTOR, FUEL RETUR PIPE AD FUEL PRESSURE REGULATOR ASSEMBLY REMOVAL! CAUTIO Be careful not to drop the fuel injector when the delivery pipe is removed. The delivery pipe must be removed with the fuel injector, fuel return pipe and fuel pressure regulator attached. ISTALLATIO SERVICE POIT >>A<< O-RIG/ FUEL HIGH-PRESSURE HOSE ISTALLATIO! CAUTIO Do not let the engine oil get into the delivery pipe, or it will be damaged. 1. Apply a drop of new engine oil to the O-ring.

15 ITAKE AD EXHAUST ILET MAIFOLD 2. Turn the fuel high-pressure hose to the right and left to install to the delivery pipe. Be careful not to damage the O-ring. After installing, check that the fuel high-pressure hose turns smoothly. 3. If the fuel high-pressure hose does not turn smoothly, the O-ring may be trapped. Remove the fuel high-pressure hose, re-install the fuel high-pressure hose into the delivery pipe and check again. 4. Tighten the fuel high-pressure hose to the specified torque. Tightening torque: 5.0 ± 1.0 m ISPECTIO M Check the following points; replace the part if a problem is found. Inlet Manifold Check 1. Check for damage or cracking of any part. 2. Clogging of the negative pressure (vacuum) outlet port, or clogging of the exhaust gas recirculation passages. 3. Using a straight edge and feeler gauge, check for distortion of the cylinder head installation surface. Standard value: 0.15 mm or less Limit: 0.20 mm

16 15-16 ITAKE AD EXHAUST EXHAUST MAIFOLD AD TURBOCHARGER EXHAUST MAIFOLD AD TURBOCHARGER REMOVAL AD ISTALLATIO M Pre-removal Operation Under Cover Removal (Refer to GROUP 51, Front Bumper P.51-3). Radiator Removal (Refer to GROUP 14, Radiator P.14-26). Air Intake Hose Removal (Refer to P.15-6). Air Pipe A, Air Pipe B, Air Pipe C, Air Hose A and Air Hose D Removal (Refer to P.15-7). Crossmember Bar Removal (Refer to GROUP 32, Engine Roll Stopper, Centremember P.32-8). Front Exhaust Pipe Removal (Refer to P.15-19). Post-installation Operation Front Exhaust Pipe Installation (Refer to P.15-19). Crossmember Bar Installation (Refer to GROUP 32, Engine Roll Stopper, Centremember P.32-8). Air Pipe A, Air Pipe B, Air Pipe C, Air Hose A and Air Hose D Installation (Refer to P.15-7). Air Intake Hose installation (Refer to P.15-6). Radiator Installation (Refer to GROUP 14, Radiator P.14-26). Under Cover Installation (Refer to GROUP 51, Front Bumper P.51-3). 23 ± 3 m 1 64 ± 5 m ± 3 m 29 ± 3 m 14 ± 1 m 44 ± 5 m ± 5 m ± 5 m 31 ± 2 m 8 17 ± 2 m ± 1 m ± 1 m 59 ± 5 m ± 7 m ± 7 m ± 6 m 19 ± 1 m 9.0 ± 1.0 m 14 ± 1 m Removal steps 1. Exhaust manifold cover <<A>> >>D<< 2. Oxygen sensor (Front) 3. Turbocharger heat protector 4. Turbocharger water feed pipe connection ± 1 m AC2648 AB Removal steps (Continued) 5. Gaskets 6. Turbocharger water return hose connection <<B>> 7. Turbocharger oil feed pipe 8. Gaskets

17 ITAKE AD EXHAUST EXHAUST MAIFOLD AD TURBOCHARGER Removal steps (Continued) Starter motor (Refer to GROUP 16, Starting System Starter Motor Assembly P.16-20). 9. Turbocharger oil return pipe >>C<<. Turbocharger oil return pipe gasket 11. Turbocharger oil return pipe gasket 12. Vacuum hose connection 13. Air outlet fitting >>B<< 14. Air outlet fitting gasket 15. Vacuum hose connection 16. Exhaust fitting bracket 17. Turbocharger and exhaust fitting assembly 18. Turbocharger gasket >>A<< 19. Turbocharger assembly 20. Exhaust fitting gasket 21. Exhaust fitting assembly 22. Turbocharger water return pipe and hose assembly 23. Gaskets 24. Exhaust manifold 25. Exhaust manifold gasket REMOVAL SERVICE POITS <<A>> OXYGE SESOR (FROT) REMOVAL ISTALLATIO SERVICE POITS >>A<< TURBOCHARGER ASSEMBLY ISTALLATIO AC2649AB 1. Clean the oil pipe and water pipe fitting, the inside of eye bolts, and individual pipe for clogs.! CAUTIO Take care not to allow foreign objects to get into the turbocharger assembly. 2. Clean or use compressed air to remove any carbon particles stuck to the oil passage of the turbocharger assembly. 3. Refill new engine oil at the oil feed pipe fitting hole of the turbocharger assembly. >>B<< AIR OUTLET FITTIG GASKET ISTALLATIO MD Turbocharger assembly Protrusion ACX02426 AB View A Use special tool oxygen sensor wrench (MD998770) to remove the oxygen sensor (front). <<B>> TURBOCHARGER OIL FEED PIPE REMOVAL! CAUTIO Take care not to allow foreign objects to get into the oil passage hole of the turbocharger assembly after the turbocharger oil feed pipe is removed. A AC2650 AB Install the gasket so that its protrusion faces in the direction shown in the illustration.

18 15-18 ITAKE AD EXHAUST EXHAUST MAIFOLD AD TURBOCHARGER >>C<< TURBOCHARGER OIL RETUR PIPE GASKET ISTALLATIO Turbocharger oil return pipe Turbocharger oil return pipe gasket protrusion AC2682AB Install the gasket so that its protrusion faces in the direction shown in the illustration. >>D<< OXYGE SESOR (FROT) ISTALLATIO ISPECTIO M Check the following points; replace the part if a problem is found. Exhaust Manifold Check 1. Check for damage or cracking of any part. 2. Using a straight edge and a feeler gauge, check for distortion of the cylinder head installation surface. Standard value: 0.15 mm or less Limit: 0.20 mm Turbocharger Assembly Check Compressor wheel MD ACX02426 AB Use special tool oxygen sensor wrench (MD998770) to install the oxygen sensor (front). AC2683AB 1. Visually check the turbine wheel and the compressor wheel for cracking or other damage. 2. Check whether the turbine wheel and the compressor wheel can be easily turned by hand. 3. Check for oil leakage from the turbocharger assembly. 4. Check whether or not the turbocharger waste gate regulating valve remains open. If any problem is found, replace the part after disassembly.

19 ITAKE AD EXHAUST EXHAUST PIPE AD MAI MUFFLER EXHAUST PIPE AD MAI MUFFLER REMOVAL AD ISTALLATIO M ± 2 m ± 2 m ± m ± 5 m ± m 6 50 ± 5 m 13 ± 2 m Exhaust main muffler removal steps 1. Exhaust main muffler 3. Exhaust pipe gasket 5. Exhaust muffler hangers Centre exhaust pipe removal steps 2. Centre exhaust pipe 3. Exhaust pipe gasket 4. Exhaust pipe gasket 6. Exhaust pipe hanger AC3642AB Front exhaust pipe removal steps Under cover (Refer to GROUP 51, Front Bumper Assembly P.51-3). Crossmember bar (Refer to GROUP 32, Engine Roll Stopper, Centremember P.32-8). 7. Springs 8. Front exhaust pipe 9. Seal ring. Exhaust pipe gasket 11. Exhaust pipe hangers

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