1998 MITSUBISHI LANCER EVOLUTION IV Workshop Manual

ENGINE COOLING – Radiator14-9
Battery voltageTerminal number
1234
When deenergized
When energized
Radiator fan motor relay HI

15-1
INTAKE AND
EXHAUST
CONTENTS
SERVICE SPECIFICATIONS 2. . . . . . . . . . . . . .
SPECIAL TOOL 2. . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE 2. . . . . . . . . . . . . . . . . .
1. Turbocharger Boost Pressure Check 2. . . .
2. Boost Pressure Control System Check 3. .
3. Wastegate Actuator Check 4. . . . . . . . . . . . .
4. Wastegate Solenoid Valve Check 4. . . . . . .
5. Air Bypass Valve Check 4. . . . . . . . . . . . . . .
6. Secondary Air Control System Check 5. . .
7. Secondary Air Control Solenoid Valve
Check 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8. Secondary Air Valve Check 6. . . . . . . . . . . .
9. Vacuum Tank Check 6. . . . . . . . . . . . . . . . . . .
INTERCOOLER 7. . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CONTROL VALVE 8. . . . . . . . . . . . . . . . . . .
INTAKE MANIFOLD 9. . . . . . . . . . . . . . . . . . . . . .
EXHAUST MANIFOLD AND
TURBOCHARGER 11. . . . . . . . . . . . . . . . . . . . . .
EXHAUST PIPE AND MUFFLER 14. . . . . . . .

INTAKE AND EXHAUST –
Service Specifications /
Special Tool / On-vehicle Service15-2
SERVICE SPECIFICATIONS
ItemsStandard valueLimit
Turbocharger boost pressure kPa {kg/cm2}53 – 87 {0.54 – 0.89}–
Wastegate actuator activation pressure kPa {kg/cm2}Approx. 100 {1.02}–
Wastegate solenoid valve coil resistance (at 20
C) Ω62 – 74–
Air bypass valve activation pressure kPa {mmHg}Approx. 53 {400}–
Secondary air control solenoid valve coil resistance (at 20
C) Ω28 – 36–
Intake manifold and exhaust manifold mounting surface distortion
mmWithin 0.150.20
SPECIAL TOOL
ToolNumberNameApplication
MB998770Oxygen sensor
wrenchRemoval and installation of oxygen sensor
ON-VEHICLE SERVICE
1. TURBOCHARGER BOOST PRESSURE
CHECK
Caution
Carry out driving tests in a location where full-throttle
acceleration is possible with utmost safety. Two persons
should be in the vehicle during the test, the assistant
in the front passenger seat reading the pressure gauge.
(1) Disconnect the hose (black) from the boost pressure
control solenoid valve and fit the pressure gauge to this
hose.
After the hose (black) has been disconnected, fit a blank
plug to the solenoid valve nipple.
(2) Drive at full-throttle acceleration in second gear and
measure the boost pressure when the engine speed
exceeds about 3,000 r/min.
Standard value:
53 – 87 kPa {0.54 – 0.89 kg/cm
2}
59 – 84 kPa {0.61 – 0.86 kg/cm2}
Wastegate
solenoid valve
Blank plug

INTAKE AND EXHAUST – On-vehicle Service15-3
(3) If the boost pressure is lower than the standard value,
check for following which are probably the cause:
Wastegate actuator inoperative
Boost pressure leak
Turbocharger defective
(4) If the boost pressure is higher than the standard value,
boost pressure control is probably faulty. Make the
following checks:
Wastegate actuator inoperative
Wastegate valve inoperative
Wastegate actuator rubber hose disconnected or
cracked
2. BOOST PRESSURE CONTROL SYSTEM
CHECK
(1) Disconnect the hose (black) from the wastegate solenoid
valve and connect a three-way joint between the hose
and solenoid valve.
(2) Connect a hand vacuum pump to the three-way joint.
(3) Disconnect the hose (black) from the intake pipe nipple
connected to the turbocharger compressor housing and
fit a blank plug to this nipple.
(4) Disconnect the negative cable from the battery, keep it
disconnected for 10 sec. or more, and then reconnect
it back again.
(5) Block and unblock the end of the vacuum hose (black)
with a finger to apply vacuum and check for the vacuum
condition.
Engine conditionHose (black) endNormally
Stationary
(ignition switch: ON)
UnblockedVacuum leaks.
(ignition switch: ON)
BlockedVacuum retained.
Idling after warmupVacuum leaks.
NOTE
If the vacuum condition is faulty, the wastegate actuator,
wastegate solenoid valve, or hose is probably defective.
Wastegate
solenoid valve

INTAKE AND EXHAUST – On-vehicle Service15-4
3. WASTEGATE ACTUATOR CHECK
(1) Connect a hand pump (pressure type) to the nipple.
(2) Gradually increase the pressure being applied to check
for the pressure at which the wastegate actuator rod starts
moving (approx. 1 mm stroke).
Standard value: Approx. 100 kPa {1.02 kg/cm
2}
Caution
Do not apply a pressure more than 120 kPa {1.23
kg/cm
2} to prevent the diaphragm from being
damaged.
(3) If the pressure drastically deviates from the standard
value, check the actuator or wastegate valve and, if
necessary, replace the actuator or turbocharger assembly.
4. WASTEGATE SOLENOID VALVE CHECK
4-1 OPERATION CHECK
(1) Connect a hand vacuum pump to nipple A of the solenoid
valve.
(2) Using jumper wires, connect the solenoid valve terminal
to battery terminals.
(3) Disconnecting and reconnecting the jumper wire on the
(–) terminal side, apply vacuum to check for airtightness.
Jumper wireNipple B conditionNormally
ConnectedOpenVacuum leaks.
PluggedVacuum retained.
DisconnectedOpenVacuum retained.
4-2 COIL RESISTANCE CHECK
Measure the resistance across solenoid valve terminals.
Standard value: 62 – 74 Ω (at 20
C)
5. AIR BYPASS VALVE CHECK
(1) Remove the air bypass valve.
(2) Connect a hand vacuum pump to the air bypass valve
nipple.
(3) Apply a vacuum of approx. 45 kPa {340 mmHg} and
check that the valve is airtight.
(4) Increase the vacuum and check for valve operation.
VacuumValve operation
Approx. 53 kPa {400 mmHg}Starts moving

INTAKE AND EXHAUST – On-vehicle Service15-5
6. SECONDARY AIR CONTROL SYSTEM
CHECK
(1) Start the engine and let it run at idle speed.
(2) Short-circuit the no. 6 terminal of the engine ECU
connector using a jumper wire and check at this time
that the secondary air valve lifts.
At this time, the engine ECU connector should be
connected.
7. SECONDARY AIR CONTROL SOLENOID
VALVE CHECK
7-1 OPERATION CHECK
(1) Disconnect the vacuum hose (white stripe, yellow stripe)
from the solenoid valve.
(2) Disconnect the harness connector.
(3) Connect a hand vacuum pump to nipple A of the solenoid
valve.
(4) Using jumper wires, connect the solenoid valve terminal
to battery terminals.
(5) Disconnecting and reconnecting the jumper wire on the
(–) terminal side, apply vacuum to check for airtightness.
Jumper wireNipple B conditionNormally
ConnectedOpenVacuum leaks.
PluggedVacuum retained.
DisconnectedOpenVacuum leaks.
7-2 COIL RESISTANCE CHECK
Measure the resistance across solenoid valve terminals.
Standard value: 28 – 36 Ω (at 20
C)
Secondary air control
solenoid valve
Battery

INTAKE AND EXHAUST – On-vehicle Service15-6
8. SECONDARY AIR VALVE CHECK
(1) Remove the secondary air valve.
(2) Connect a hand vacuum pump to the secondary air valve
nipple.
(3) Apply a vacuum of 67 kPa {500 mmHg} and check that
the vacuum is retained.
(4) Blow air from side (A) and side (B) of the secondary
air valve to check for air passage.
VacuumAir blowing directionAir passage
0 kPa
(vacuum not applied)(A) → (B)No
40 kPa {300 mmHg}
or more
(A) → (B)Ye s
or more
(B) → (A)No
9. VACUUM TANK CHECK
(1) Connect a hand vacuum pump to nipple A of the vacuum
tank. Applying a vacuum of 67 kPa {500 mmHg}, check
that the vacuum is retained.
(2) Connect a hand vacuum pump to nipple B of the vacuum
tank.
(3) Apply a vacuum of 67 kPa {500 mmHg] with nipple A
plugged with a finger. Check that the vacuum leaks when
the finger is then released.
A
B
A
B

INTAKE AND EXHAUST – Intercooler15-7
INTERCOOLER
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Front Bumper Removal and Installation
(Refer to GROUP 51.)
16
Unit: Nm {kgf
m}
10 – 13
{1.0 – 1.3} 6 {0.6}
10 – 13
{1.0 – 1.3} 10 – 13
{1.0 – 1.3}
10 – 13
{1.0 – 1.3}
11 1 0
1213
15
1454 2
36 7
9 8
Hose clamp
tightening torque
1
Removal steps
1. Vacuum hose connection
2. Air bypass valve assembly
3. Breather hose connection
4. Vacuum hose connection
5. Air intake hose assembly
A6. Air bypass hose
7. Air hose connection
A8. Air hose DA9. Air hose C
A10. Air hose A
11. Air pipe A
A12. Air hose B
13. Intercooler assembly
A14. Air hose B
15. Air pipe B
16. Air pipe bracket
INSTALLATION SERVICE POINT
AAIR HOSE B / AIR HOSE A / AIR HOSE C / AIR
HOSE D / AIR BYPASS HOSE INSTALLATION
Align the alignment mark (white paint) on each hose with
the protrusion on each pipe.