Mitsubishi Outlander XL. Manual - part 435

GROUP 15

INTAKE AND EXHAUST

CONTENTS

GENERAL INFOMATION..............

15-2

SERVICE SPECIFICATION...........

15-2

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

15-2

INTAKE MANIFOLD TUNING SYSTEM CHECK
................................

15-2

INTAKE MANIFOLD TUNING SOLENOID
CHECK...........................

15-2

VACUUM TANK CHECK <6G7>.........

15-3

INTAKE AND EXHAUST DIAGNOSIS
................................

15-3

INTRODUCTION....................

15-3

TROUBLESHOOTING STRATEGY........

15-4

SYMPTOM CHART...................

15-4

SYMPTOM PROCEDURES..............

15-4

Inspection Procedure 1: Exhaust
Leakage..........................

.15-4

Inspection Procedure 2: Abnormal Noise
..................................

15-4

SPECIAL TOOLS...................

15-5

AIR CLEANER.....................

15-6

REMOVAL AND INSTALLATION........

15-6

INTAKE MANIFOLD PLENUM.........

.15-7

REMOVAL AND INSTALLATION........

15-7

INTAKE MANIFOLD.................

15-8

REMOVAL AND INSTALLATION........

15-8

INSPECTION.....................

15-11

EXHAUST MANIFOLD...............

15-11

REMOVAL AND INSTALLATION.......

15-11

INSPECTION.....................

15-15

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

15-16

REMOVAL AND INSTALLATION.......

15-16

15-1

GENERAL INFOMATION

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The exhaust pipe is divided into four parts.

SERVICE SPECIFICATION

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Item

Standard value

Limit

Intake manifold tuning solenoid coil resistance [at 20°
C (68°F)] Ω

29 - 35

-

Intake  manifold  distortion  of  the  installation  surface
mm (in)

0.15 (0.006) or less

0.20 (0.008)

Exhaust manifold distortion of the installation surface
mm (in)

0.7 (0.028) or less

0.5 (0.020)

ON-VEHICLE SERVICE

INTAKE MANIFOLD TUNING SYSTEM CHECK

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1.

Warm up the engine.

ZK600341

Intake manifold
tuning solenoid

Intake manifold
tuning actuator

AA00

2.

Disconnect the vacuum hose from the intake manifold tuning
(IMT) actuator, and then connect a vacuum gauge via the Tee-
fitting.

3.

Start  the  engine  and  verify  that  a  vacuum  is  applied  to  the
vacuum gauge.

4.

As  described  in  the  chart  below,  vary  the  engine  speed  to
inspect the vacuum conditions. During this inspection, verify
that the rod of the IMT actuator is operating.

ENGINE SPEED

NORMAL
CONDITION

CONTROL
VALV

3,750 r/min or less

Vacuum
maintained

Closed

Within  3,750  r/min  or
less, engine is suddenly
raced

Vacuum

 not

change

Closed

4,050 r/min or more

Vacuum leaks

Open

INTAKE MANIFOLD TUNING SOLENOID CHECK

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1.

Disconnect the vacuum hoses from the intake manifold tuning
(IMT) solenoid.

NOTE: 

When disconnecting the vacuum hose, always make

sure that it can be reconnected at its original position.

2.

Disconnect the harness connector.

15-2

INTAKE AND EXHAUST

GENERAL INFOMATION

ZK600342

B

A

AA00

3.

Connect  a  hand  vacuum  pump  to  nipple  (B)  of  the  IMT
solenoid.

4.

As  described  in  the  chart  below,  check  airtightness  by
applying  a  vacuum  with  voltage  applied  directly  from  the
battery to the IMT solenoid, and without applying voltage.

BATTERY
POSITIVE
VOLTAGE

NIPPLE

 (A)

CONDITION

NORMAL
CONDITION

Applied

Open

Vacuum leaks

Closed

Vacuum
maintained

Not applied

Open

Vacuum leaks

ZK600343AA00

5.

Measure  the  resistance  between  the  terminals  of  the  IMT
solenoid.

Standard value: 29 - 35 Ω [at 20°C (68°F)]

6.

Replace solenoid resistance is out of specification.

VACUUM TANK CHECK <6G7>

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ZK600344

A

B

AA00

1.

Disconnect the vacuum hoses from the vacuum tank.

NOTE: 

When disconnecting the vacuum hose, always make

sure that it can be reconnected at its original position.

2.

Connect a hand vacuum pump to nipple "A" of the vacuum
tank, apply a vacuum of 67 kPa (19.7 in.Hg), and verify that
the vacuum is maintained.

3.

Disconnect  the  hand  vacuum  pump  from  nipple  "A"  and
connect it to nipple "B".

4.

Block nipple "A" with your finger and apply a vacuum of 67 kPa
(19.7 in.Hg) to nipple "B". Release your finger from nipple "A"
and verify that the vacuum leaks immediately.

5.

Replace the vacuum tank if it is faulty.

INTAKE AND EXHAUST DIAGNOSIS

INTRODUCTION

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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.

INTAKE AND EXHAUST

15-3

ON-VEHICLE SERVICE

TROUBLESHOOTING STRATEGY

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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

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Symptom

Inspection procedure

Reference page

Exhaust leakage

1

 P.15-4

Abnormal noise

2

 P.15-4

SYMPTOM PROCEDURES

Inspection Procedure 1: Exhaust Leakage

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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

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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.

15-4

INTAKE AND EXHAUST

INTAKE AND EXHAUST DIAGNOSIS