INTAKE AND EXHAUST - Evoscan

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15-1INTAKE ANDEXHAUSTCONTENTSGENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2Vacuum Tank Check . . . . . . . . . . . . . . . . . . . . . . . . . 7SERVICE SPECIFICATION . . . . . . . . . . . . . . . . . . 3AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3INTERCOOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 3INTERCOOLER WATER SPRAY . . . . . . . . . . . . 10Turbocharger Supercharging Pressure Check . . . 3Supercharging Pressure Control SystemCheck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Waste Gate Actuator Check . . . . . . . . . . . . . . . . . . . 4SECONDARY AIR SUPPLY SYSTEM . . . . . . . 14INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . 16Waste Gate Solenoid Valve Check . . . . . . . . . . . . . 5EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . 19Air Bypass Valve Check . . . . . . . . . . . . . . . . . . . . . . 5TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . 22Intake Manifold Pressure Check . . . . . . . . . . . . . . . 6Secondary Air Control System Check . . . . . . . . . . 6EXHAUST PIPE AND MAIN MUFFLER . . . . . 26Secondary Air Control Solenoid Valve Check . . . 6CATALYTIC CONVERTER. . . . . . . . . . . . . . . . . . . . (REFER TO GROUP 17.)Secondary Air Valve Check . . . . . . . . . . . . . . . . . . . 7

15-2INTAKE AND EXHAUST - General InformationGENERAL INFORMATIONSUPERCHARGING PRESSURE CONTROLBy controlling the duty of the waste gate solenoid valve, the waste gate actuator functions to control the superchargingpressure. This allows a supercharged pressure matching the engine operation state to be attained. Control is carriedout to prevent excessive supercharging and thereby prevent engine damage.SECONDARY AIR CONTROLWhen decelerating during high-speed travel, the secondary air is introduced into the upstream of the turbochargerto prevent the turbine speed from dropping and to increase the acceleration responsiveness after deceleration.The secondary air is introduced into each cylinder of the exhaust manifold to maximize the effect.VacuumtankSecondary aircontrol solenoidvalveSecondaryair valveTurbochargerAirinletWaste gatesolenoidvalveWaste gateactuator

INTAKE AND EXHAUST -Service Specifications/Special Tool/On-vehicle Service15-3SERVICE SPECIFICATIONSItemStandard valueLimitTurbocharger supercharging pressure (waste gate solenoidvalve not operating) kPa59 - 84-Initial activation pressure of waste gate actuator (at the strokeof approximately 1 mm) kPaApproximately 100-Waste gate solenoid valve coil resistance (at 20 C) Ω29 - 35-Initial activation pressure of air bypass valve kPaApproximately 53-Secondary air control solenoid valve coil resistance(at 20 C) Ω29 - 35-Manifold distortion of the installation surface mm0.15 or less0.20SPECIAL TOOLToolWaste gatesolenoid valveNumberNameUseMD998770Oxygen sensor wrenchRemoval and installation of oxygen sensorThrottle bodyON-VEHICLE SERVICETURBOCHARGER SUPERCHARGINGPRESSURE CHECKCautionTwo persons should be in the vehicle when the test isconducted; the person in the passenger seat should readthe indications shown by the pressure meter.Plug1. Disconnect the hose (black) from the turbocharger wastegate solenoid valve, and connect the pressure gaugeto the hose. Plug the nipple of the solenoid valve fromwhich the hose (black) has been disconnected.2. Drive at full-throttle acceleration in second gear and thenmeasure the supercharging pressure when the enginespeed in about 3,000 r/min.Standard value: 59 – 84 kPa3. If the supercharging pressure deviates from the standardvalue, check the following items for possible cause.D Malfunction of the waste gate actuatorD Leakage of supercharging pressureD Malfunction of the turbocharger

15-4INTAKE AND EXHAUST - On-vehicle Service4. When the indicated supercharging is more than standardvalue, supercharging control may be faulty, thereforecheck the followings.D Malfunction of the waste gate actuatorD Malfunction of waste gate valveD Disconnection or cracks of the waste gate actuatorrubber hoseThrottle bodySUPERCHARGING PRESSURE CONTROLSYSTEM CHECK1. Disconnect the hose (black) from the turbocharger wastegate solenoid valve and connect a three-way joint betweenthe hose and the solenoid valve.2. Connect a hand vacuum pump to the three-way joint.Waste gatesolenoid valve3. Disconnect the hose from the turbocharger waste gateactuator 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 andwhen it is open.Waste gateactuatorBoost hoseEngine stateHose endNormal stateStopp (Ignition(gswitch:it h “ON”position)OpenedNegative pressure leaks.ClosedNegative pressure ismaintained.Idling (afterwarm-up)Negative pressure leaks.NOTEIf this check indicates an abnormal condition, theturbocharger waste gate actuator, turbocharger wastegate solenoid or hose is broken.WASTE GATE ACTUATOR CHECK1. Connect a manual pump (pressure-application type) tonipple.2. While gradually applying pressure, check the pressure thatbegins to activate (approximately 1 mm stroke) the wastegate actuator rod.Standard value: Approximately 100 kPaCautionIn order to avoid damage to the diaphragm, do notapply a pressure of 117 kPa or higher.

15-5INTAKE AND EXHAUST - On-vehicle Service3. If there is a significant deviation from the standard value,check the actuator or the waste gate valve: replaceactuator or turbocharger assembly if necessary.WASTE GATE SOLENOID VALVE CHECKABBatteryOPERATION CHECK1. Connect a hand vacuum pump to the solenoid valve nippleA.2. Using a jumper wire, connect between the solenoid valveterminal and battery terminal.3. Connecting and disconnecting the jumper wire at thebattery negative terminal to apply a negative pressure,check tightness.Jumper wireB nippleconditionNormal conditionConnectedOpenedNegative pressure leaks.ClosedNegative pressure is held.OpenedNegative pressure is held.DisconnectedCOIL RESISTANCE CHECKMeasure the resistance between solenoid valve terminals.Standard value: 29 – 35 Ω (at 20 C)AIR BYPASS VALVE CHECK1. Remove the air bypass valve.2. Connect the hand vacuum pump to the nipple of theair bypass valve.3. Apply a negative pressure of approximately 49 kPa, andcheck that air tightness is maintained.4. Also check operation of the valve.Standard value:Negative pressureApproximately 53 kPaValve operationIt starts opening

15-6INTAKE AND EXHAUST - On-vehicle ServiceINTAKE MANIFOLD PRESSURE CHECKRefer to GROUP 11A – On-vehicle Service.SECONDARY AIR CONTROL SYSTEM CHECK1. Start the engine and carry out idling.2. Confirm that the secondary air valve lifts up when theengine-ECU connector No. 53 terminal is short-circuitedwith the earth using a jumper wire.The engine-ECU connector must be connected at thistime.Secondaryair controlsolenoidvalveVacuum tankSECONDARY AIR CONTROL SOLENOIDVALVE CHECKOPERATION CHECK1. Disconnect the vacuum hose (white-striped, yellowstriped) from the solenoid valve.2. Separate the harness connector.3. Connect the hand vacuum pump to the solenoid valve’sA nipple.4. Connect the solenoid valve terminal and battery terminalwith a jumper wire.5. Disconnect the jumper wire between the battery’s ( - )terminals, apply a negative pressure, and inspect thetightness.BABatteryJumper wireState of BnippleNormal stateConnectedOpenedNegative pressure leaks.ClosedNegative pressure ismaintained.ClosedNegative pressure leaks.Disconnected

15-7INTAKE AND EXHAUST - On-vehicle ServiceCOIL RESISTANCE CHECKMeasure the resistance between the solenoid valve terminals.Standard value: 29 – 35 Ω (at 20 C)SECONDARY AIR VALVE CHECKAB1. Disconnect the secondary air valve.2. Connect the hand vacuum pump to the secondary airvalve’s nipple.3. Apply a negative pressure of 67 kPa, and confirm thatthe negative pressure is maintained.4. Blow in air from the (A) side and (B) side of the secondaryair valve, and inspect the ventilation.Negative pressureAir blow-indirectionAir ventilation0 kPa(State withoutnegative pressure)(A) (B)Not ventilated40 kPa or more(A) (B)Ventilated(B) (A)Not ventilatedVACUUM TANK CHECKAB1. Connect the hand vacuum pump to the vacuum tank’sA nipple. Apply a negative pressure of 67 kPa, and confirmthat the negative pressure is maintained.2. Connect the hand vacuum pump to the vacuum tank’sB nipple.3. Plug the A nipple with a finger, and apply a negativepressure of 67 kPa. Confirm that the negative pressureleaks immediately when the finger is released.

15-8INTAKE AND EXHAUST - Air CleanerAIR CLEANERREMOVAL AND INSTALLATIONCautionParts marked by * are made of recycled-paper mixed plastic material, so observe the followingprecautions.1. Avoid any shock or load to these parts when removing and installing them.2. Engage the case hinges securely when assembling these parts.NOTEParts marked by * are made of recycled-paper mixed plastic material, so can be disposed of by incineration.16.0 1.0 N·m76*24899.0 1.0 N·m9.0 1.0 N·m34.0 1.0 N·m4.0 1.0 N·m9.0 1.0 N·m9.0 1.0 N·m59.0 1.0 N·m21110Removal stepsD Battery1. Air duct2. Vacuum hoseD Air pipe E, Air by-pass valve assembly,Air by-pass hose (Refer to P.15-9.)3. Air intake hose4. Air flow sensor assembly5.6.7.8.9.10.11.GasketAir cleaner assemblyAir cleaner coverAir cleaner elementAir cleaner bodyWaste gate solenoid valveAir cleaner bracket

15-9INTAKE AND EXHAUST - IntercoolerINTERCOOLERREMOVAL AND INSTALLATIONPre-removal and Post-installation OperationD Air Cleaner Removal and Installation (Refer to P.15-8.)D Water Spray Hose Connection removal andInstallation (Refer to P.15-10.)DFront Bumper Removal and Installation (Refer toGROUP 51.)12 1 N·m6.0 1.0 N·m116.0 1.0 N·m6.0 1.0 N·m106.0 1.0 N·m456.0 1.0 N·m6.0 1.0 N·m12 1 N·m216.0 1.0 N·m3612 1 N·m6.0 1.0 N·m712 1 N·m1212 1 N·m1399.0 1.0 N·mRemoval steps1. Vacuum hose2. Air by-pass valve assembly3. Air by-pass hose4. Air hose E5. Air pipe C6. Air hose D7. Air pipe B86.0 1.0 N·m148.9.10.11.12.13.14.BracketAir hose CAir hose AAir pipe AAir hose BIntercooler assemblyAir guide

15-10INTAKE AND EXHAUST - Intercooler Water SprayINTERCOOLER WATER SPRAYPre-removal and Post-installation OperationD Under Cover Removal and Installation (Refer toGROUP 51 - Front Bumper.)DFront Bumper Removal and Installation (Refer toGROUP 51.)REMOVAL AND INSTALLATION WATER SPRAY SWITCH 1Water spray switch removal steps1. Water spray switchD Harness connector connection

INTAKE AND EXHAUST - Intercooler Water Spray15-11 WATER SPRAY NOZZLE/WATER SPRAY HOSE/WASHER TANK 6311 2 N·m7213411 2 N·m667345667 69768111076Water spray nozzle/Water sprayhose removal steps2. Water spray hose connection"AA D Tape3. Clamp4. Water spray nozzle (Upper)5. Water spray nozzle (Lower)"AA 6. Water spray hose7. Hose Joint12Washer tank removal steps2. Water spray hose connection8. Water spray motor harnessconnector connection9. Washer tank10. Water spray hose11. Water spray motor12. Packing13. Washer tank bracket

15-12INTAKE AND EXHAUST - Intercooler Water SprayINSTALLATION SERVICE POINTS"AA WATERSPRAY HOSE/TAPE INSTALLATIONAttach the water spray hose to the front bumper with a tape as shown in the illustration. Tape attachment position TapeTapeTapeTape65 mm30 mm0 mm20 mm35 mm50 mm50 mm0 mm0 mm10 mm10 mm10 mm10 mm10 mm10 mm

15-13INTAKE AND EXHAUST - Intercooler Water Spray Water spray switch INSPECTION1. WATER SPRAY SWITCH CONTINUITY CHECKSwitch ppositionTerminal No.NoAUTO1AUTONEUTRALMAN Water spray motor MANUAL EARTH23ILL ( )5ILL ( - )6ILL2. WATER SPRAY MOTOR CHECK(1) Check the water spray motor with the washer tankattached after the washer tank is supplied with water.(2) Check that the water is supplied with strong pressureafter energizing terminal number 1 with battery voltageand earthing terminal number 2.

15-14INTAKE AND EXHAUST - Secondary Air Supply SystemSECONDARY AIR SUPPLY SYSTEMREMOVAL AND INSTALLATIONPre-removal and Post-installation OperationD Air Duct Removal and Installation (Refer to P.15-8.)D Strut Tower Bar Removal and Installation (Refer to GROUP 42.)5.9 1.0 N·mAir pipe C23 4 N·m22 4 N·m522 4 N·m10 3411 1 N·m24 3 N·m98614 1 N·m20 2 N·m11149 5 N·m14 1 N·m714 1 N·m7Removal steps1. Control harness connectorconnection2. Heat protector3. Vacuum hose connectionD Air pipe C (Refer to P.15-9.)4. Vacuum pipe5. Secondary air hose26. Secondary air pipe assembly"AA 7. Gasket"BA 8. Gasket9. Secondary air control valve10. Engine hanger11. Secondary air control valve bracket

INTAKE AND EXHAUST - Secondary Air Supply System15-15INSTALLATION SERVICE POINTSSalient"AA GASKET INSTALLATIONInstall the gasket so that its salient can face towards thedirection as shown in the illustration.Secondary air pipe assemblyProtrusion"BA GASKET INSTALLATIONInstall the gasket so that its protrusion can face towards thedirection as shown in the illustration.

15-16INTAKE AND EXHAUST - Intake ManifoldINTAKE MANIFOLDREMOVAL AND INSTALLATIONPre-removal and Post-installation OperationD Air Duct Removal and Installation (Refer to P.15-8.)D Strut Tower Bar Removal and Installation(Refer to GROUP 42.)D Under Cover Removal and Installation(Refer to GROUP 51 - Front Bumper.)D Engine Coolant Draining and Supplying(Refer to GROUP 14 - On-vehicle Service.)D Throttle Body Removal and Installation (Refer toGROUP 13A - Throttle Body.)DDDDCrossmember Bar Removal and Installation (Referto GROUP 32 - Engine Roll Stopper, Centermember.)Front Exhaust Pipe Removal and Installation (Referto GROUP 15 - Exhaust Pipe and Main Muffler.)Secondary Air Control Valve Bracket Removal andInstallation (Refer to P.15-14.)Engine Oil Draining and Supplying1911 1 N·m148145.0 1.0 N·m103.0 0.5 N·m47811123265(Engine oil)13151713 1 N·m1618(Engine oil)Removal steps1. Center cover2. Oxygen sensor connectorconnection3. Injector connector connection4. Fuel pressure solenoid valveconnector connection5. Purge control solenoid valveconnector connection6. Knock sensor connector connection7. Vacuum hose connection8. Vacuum hose9. Fuel return hose connection"AA 10. Fuel high-pressure hose connection11. O-ringAA"12. Delivery pipe, Injector and fuelpressure regulator assembly13. Insulator14. Insulator15. Oil level gauge and guide16. O-ring17. Brake booster vacuum hoseconnection18. Purge hose connection

15-17INTAKE AND EXHAUST - Intake Manifold5.0 1.0 N·m20 2 N·m2520 2 N·m2620 2 N·m29232128222311 1 N·m1930242036 6 N·m2720 2 N·m239.0 1.0 N·m22 4 N·m9.0 1.0 N·m9.0 1.0 N·m31 3 N·m19.20.21.D22.Vacuum hoseFuel pressure solenoid valvePCV hoseAlternator (Refer to GROUP 16.)Vacuum hose and Vacuum pipeassembly connecting bolt23. Vacuum tank, EGR solenoid valve,Secondary air control solenoidvalve, Vacuum hose assembly24.25.26.27.28.29.30.Intake manifold stayEGR valveEGR gasketAlternator brace stayIntake manifoldIntake manifold gasketPurge control solenoid valveassemblyREMOVAL SERVICE POINTSAA" DELIVERY PIPE, INJECTOR AND FUELPRESSURE REGULATOR ASSEMBLY REMOVALThe delivery pipe must be removed with the injector andfuel pressure regulator attached.CautionTake care not to drop delivery pipe, injector, or fuelpressure regulator assembly when removing those parts.

15-18INTAKE AND EXHAUST - Intake ManifoldINSTALLATION SERVICE POINTS"AA FUEL HIGH-PRESSURE HOSE CONNECTION1. Apply a drop of new engine oil to the O-ring.CautionBe sure not to let engine oil enter the delivery pipe.2. While turning the injector, high-pressure fuel hose andfuel pressure regulator to the right and left, install thedelivery pipe, while being careful not to damage the O-ring.After installing, check that the hose turns smoothly.3. If it does not turn smoothly, the O-ring may be trapped,remove the injector, high-pressure fuel hose or fuelpressure regulator and then re-insert it into the deliverypipe and check once again.4. Tighten the high-pressure fuel hose to the specified torque.Tightening torque: 5.0 1.0 N mINSPECTIONCheck the following points; replace the part if a problem isfound.INTAKE MANIFOLD CHECK1. 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 mmLimit: 0.20 mm

15-19INTAKE AND EXHAUST - Exhaust ManifoldEXHAUST MANIFOLDREMOVAL AND INSTALLATIONPre-removal and Post-installation OperationD Under Cover Removal and Installation(Refer to GROUP 51 - Front bumper.)D Radiator Removal and Installation(Refer to GROUP 14.)D Air Intake Hose Removal and Installation(Refer to P.15-8.)DDDAir Pipe A, Air Pipe C, Air Hose D, Air Pipe B Removaland Installation (Refer to P.15-9.)Crossmember Bar Removal and Installation (Referto GROUP 32 - Engine Roll Stopper, Centermember.)Front Exhaust Pipe Removal and Installation(Refer to P.15-26.)14 1 N·m14 1 N·m2259 5 N·m22129 3 N·m14 1 N·m149 5 N·m417 2 N·m31 2 N·m1949 5 N·m153171844 5 N·m710 1 N·m16542 7 N·m59 5 N·m10 1 N·m11131012819 1 N·m30 3 N·m35 6 N·m42 7 N·m1191420610 1 N·m1044 5 N·m9.0 1.0 N·m14 1 N·mRemoval steps1. Exhaust manifold heat protector2. Air pipe assemblyAA"3. Oxygen sensor4. Turbocharger heat protector5. Turbocharger water feed pipeassembly connection6. Turbocharger water return hoseconnectionAB"7. Oil feed pipe8. Starter Motor9. Oil return pipe"CA 10. Oil return pipe gasket11. Vacuum hose connection30 3 N·m12."BA 13.14."AA 15.16.17.18.19.20.Air outlet fittingAir outlet fitting gasketExhaust fitting bracketTurbocharger assemblyTurbochargerExhaust fitting gasketExhaust fittingTurbocharger gasketTurbocharger water return pipeassembly connection21. Exhaust manifold22. Exhaust manifold gasket

15-20INTAKE AND EXHAUST - Exhaust ManifoldREMOVAL SERVICE POINTAA" OXYGEN SENSOR REMOVALUse special tool to remove the oxygen sensor.MD998770Oxygen sensorAB" OIL FEED PIPE REMOVALTake care not to let foreign objects get into the oil passagehole of the turbocharger after the oil feed pipe is removed.INSTALLATION SERVICE POINT"AA TURBOCHARGER INSTALLATION1. Clean the oil feed pipe, oil return pipe, water pipe fitting,the inside of eye bolt, and individual pipe for clogs.2. Clean or blow the air if carbon particles are stuck to theoil passage of the turbocharger.CautionTake care not to let foreign objects get into theturbocharger.3. Refill new engine oil at the oil feed pipe fitting hole ofthe turbocharger.TurbochargerProtrusionView AView A"BA AIR OUTLET FITTING GASKET INSTALLATIONInstall the gasket so that its protrusion can face towards thedirection as shown in the illustration.

INTAKE AND EXHAUST - Exhaust ManifoldPrint15-21"CA OIL RETURN PIPE GASKET INSTALLATIONInstall the gasket so that its print part can face towards theoil pan side.GasketINSPECTIONCheck the following points; replace the part if a problem isfound.1. EXHAUST MANIFOLD CHECK(1) Check for damage or cracking of any part.(2) Using a straight edge and a feeler gauge, check fordistortion of the cylinder head installation surface.Standard value: 0.15 mm or lessLimit: 0.20 mmCompressor wheel2. TURBOCHARGER ASSEMBLY CHECK(1) Visually check the turbine wheel and the compressorwheel for cracking or other damage.(2) Check whether the turbine wheel and the compressorwheel can be easily turned by hand.(3) Check for oil leakage from the turbocharger assembly.(4) Check whether or not the waste gate valve remains open.If any problem is found, replace the part after disassembly.

15-22INTAKE AND EXHAUST - TurbochargerTURBOCHARGERDISASSEMBLY AND REASSEMBLY86534711.3 1.5 Nm21Disassembly stepsD Inspection of turbocharger waste gateactuator operation1. E-ring2. Waste gate actuator"EA 3. Coupling"F

Removal steps D Battery 1. Air duct 2. Vacuum hose D AirpipeE,Airby-passvalveassembly, Air by-pass hose (Refer to P.15-9.) 3. Air intake hose 4. Air flow sensor assembly 5. Gasket 6. Air cleaner assembly 7. Air cleaner cover 8. Air cleaner element 9. Air cleaner body 10. Waste gate solenoid valve 11. Air cleaner bracket

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