Manual Pajero 4x4 Intake and Exhaust
-
Upload
gian-carlo-mamani-giles -
Category
Documents
-
view
220 -
download
6
Transcript of Manual Pajero 4x4 Intake and Exhaust
-
8/11/2019 Manual Pajero 4x4 Intake and Exhaust
1/20
15-1
INT AKE AND EXHAUST
CONTENTS 15109000311
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2 INTERCOOLER AND INTERCOOLERFAN-ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2INTAKE MANIFOLD . . . . . . . . . . . . . . . . . 8
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 2Intake Manifold Vacuum Check . . . . . . . . . 2
Turbocharger Supercharging Check . . . . . 2Waste Gate Actuator Check . . . . . . . . . . 3Power Relay Check . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TURBOCHARGER AND EXHAUST MANIFO LD . . . . . . . . . . . . . . . . . . . . . . 12
TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . 15
EXHAUST M ANI FO LD . . . . . . . . . . . . . 18 AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
EXHAUST PIPE AND MAIN MUFFLER . . . . 19
-
8/11/2019 Manual Pajero 4x4 Intake and Exhaust
2/20
Service S pe c i f ic a t ions /15-2 INTAKE AND EXHAUST S peci al Tool/On-vehicle Se r vic e
SERVICE SPECIFIC ATIONS 15100030128
SPEC IAL TOO L 15100060172
ON-VEHICLE SERVICEINTAKE MANIFOLD VACUUM CHECK
15100180236
Refer to GROUP 11A
TURBOCHARGERCa uti on
On-vehicle Service
SUPERCHARGING CHECK15100100102
Conduct the driving test in a location where driving a full acceleration can be done with safety. Two per son should be in the vehicle when the test is conducted; the person in the passenger seat should read the indic a t ions shown by the pressure m e t e r .1. Remove the boost compensator hose from the fuel
injection pump, and install a pressure gauge as shown in the illustration.Drive at full-throttle acceleration in second gear and then measure the supercharging when the engine speed in about 3,000 r/min.When the indicated supercharging does not become positive pressure, check the following items.
2.
3.
Malfunction of the waste gate actuator. Leakage of supercharging pressure.
Malfunction of the turbocharger.4. When the indicated supercharging is 84 kPa or more,supercharging control may be faulty, therefore check the followings. Disconnection or cracks of the waste gate actuator
rubber hose.Malfunction of the waste gate actuator.Malfunction of the waste gate valve.
Tool Number Name Use
MD998770 Oxygen sensor wrench
Removal/Installation of oxygen sensor
Items Standard value Limit
Waste gate actuator activation pressure kPa Approx. 83
Intake air temperature switch C OFF (no continuity) 55 or less
ON (continuity) 57
or
more
Manifold distortion of the installation surface mm 0.15 or less 0.20
-
8/11/2019 Manual Pajero 4x4 Intake and Exhaust
3/20
15-3INT AKE AND EXHAUST On-vehicle S e r vice
WASTE GATE ACTUATOR CHECK 15100120078
1. Connect a manual pump (pressure-application type) to nipple.While gradually applying pressure, check the pressure that begins to activate (approx. 1 mm stroke) the waste gate actuator rod.
Standard value: Approx. 83 kPa Ca uti on In order to avoid damage to the diaphragm, do not apply a pressure of 91 kPa or h ighe r .If there is a significant deviation from the standard value, check the actuator or the waste gate valve: replace i necessary.
2.
3.
POWER RELAY CHECK 15100620011INTERCOOLER FAN MOTOR RELAY CONTINUITY CHE CK
Battery voltage Terminal No.
1 3 4 5
Power is not supplied
Power is
supplied
-
8/11/2019 Manual Pajero 4x4 Intake and Exhaust
4/20
15-4 INTAKE AND EXHAUST A i r C leaner
AIR CLE ANE RREMOVAL AND INST ALLA TION
15100210126
8.8 Nm 4 Nm 5 7
8.8 Nm 9
1013
12
4
wit h
38.8 Nm 8.8 Nm
4 Nm
12 14
8.8 Nm
13 892 Nm 7
4 Nm
8.8 Nm 1
8.8 Nm
4 Nm
8.8 Nm 6
11 214
Removal st ep s 1. Breather hose connection2. Air intake hose3. Resonator
4. Resonator 5. Air frow sensor assembly 6. Air intake hose 7. Air cleaner cover8. Bolt
9. Air cleaner element10. Air duct
11. Air duct
12. Pre-cleaner assembly
13. Air cleaner body14. Air cleaner bracket
-
8/11/2019 Manual Pajero 4x4 Intake and Exhaust
5/20
15-5INTAKE AND EXHAUST Intercooler and Inter cool er Fan -ECU
INTERCOOLER AND INTE RCOOL ER F A N-ECU 15100420079REMOV AL AND INST ALLA TION
39 Nm
64
1
729 Nm
5
9
9 Nm
Intercooler fan-ECU removal st ep s 1. Scuff plate2. Cowl side trim3. Intercooler fan-ECU
Intercooler removal s t e p s 4. Intake air temperature switch
connector5. Intercooler fan motor connector6. Air hose B connection (Intake
manifold side)7. Air hose A-2 connection (Turbochar-
ger side)8. Intercooler and bracket assembly
-
8/11/2019 Manual Pajero 4x4 Intake and Exhaust
6/20
15-6 INTAKE AND EXHAUST Inter cool er and Intercooler Fan -ECU
DISASSEMB LY AND REASSEMB LY 15100660020
64 9 Nm 1
6 Nm
105
6 Nm
79 Nm 3
29 Nm
9
8
Disassembly st
ep s 1. Air hose A-22. Blanch tube3. Blanch tube bracket4. Intercooler cover5. Air hose A-1
6. Air hose B7. Intake air temperature switch8. Intercooler bracket9. Fan and motor assembly
10. Intercooler
INSPECTION 15100430027 Check the intercooler fins for bending damage or foreign
matter.Check the intercooler hoses for cracking, damage or wear.
-
8/11/2019 Manual Pajero 4x4 Intake and Exhaust
7/20
15-7INTAKE AND EXHAUST Intercooler and Intercooler Fan -ECU
INTAKE AIR TEMPERATURE SWITCH CHECK15100630014
1. Immerse the intake air temperature switch in the hot water shown in the figure.
2. When changing the water temperature, check for continuity between the terminals with the circuit tester.Standard va lue :
(Temperature at point B)
Temperature Continuity
Less than 55 C(Temperature at point A)
OFF (No continuity)
More than 57 C ON (Continuity)B
ON
OFF Water temperature
A
-
8/11/2019 Manual Pajero 4x4 Intake and Exhaust
8/20
15-8 INTAKE AND EXHAUST Intake Manifold
INTAKE MANIFOLD 15100300663REMOVAL AND INST ALLA TION
18 Nm 22 Nm 9 Nm 10 12 Nm
10 12 Nm 17 20 Nm
412
1118 Nm
5
17 20 Nm
7 9 Nm 6
16
91
1518 Nm 2
1824 Nm 17
8 13
1918 Nm
18 Nm
14
10 3 35 Nm
Removal st ep s 1. Ignition coils2. Brake booster vacuum hose
connection
3. PCV
hose connection4. Crankshaft position sensor and
cam position sensor connector5. Accelerator cable bracket6. Ignition power transistor7. Water outlet fitting bracket8. Water pump stay9. Vacuum hose connection
10. Fuel pipe connection11. Solenoid valve and vacuum hose
assembly
12. EGR
valve13. EGR pipe connection14. Surge tank stay15. Throttle cable connection16. Air intake fitting17. Air intake fitting gasket18. Upper intake manifold
} D] 19. Surge tank gasket
Post-installation Oper at ion Throttle Body installation (Refer to GROUP 13A
Throttle Body.)
Pre-removal Oper at ion Fuel Discharge Prevention (Refer to GROUP 13A
On-vehicle Service.) Throttle Body Removal (Refer to GROUP 13A
Throttle Body.)
-
8/11/2019 Manual Pajero 4x4 Intake and Exhaust
9/20
m
15-9INT AKE AND EXHAUST Intake Manifold
22 12 Nm
23
219 N
2220 23 Nm
5 Nm 20
24
26
24
25
} C ] 20. High-pressure fuel hose} C ] 21. Fuel pressure regulator
22. Injector connector23. Injector and delivery pipe assembly] A} 24. Water hose connection
} B] 25. Intake manifold} A ] 26. Intake manifold gasket
REMOV AL SERVICE POINT] A} INJECTOR AND DELIVERY PIPE
REMOV A L A SSEM BLY
Remove the fuel rail (with the injectors attached to it.)Ca uti on Care must be taken when removing the fuel rail not t o drop the inje c t or .
O-ring 23
20
23 21
Engine oil
-
8/11/2019 Manual Pajero 4x4 Intake and Exhaust
10/20
15-10 INT AKE AND EXHAUST Intake Manifold
INSTALLATION SERVICE POINTS} A ] INTAKE MANIFOLD GASKET INST ALL ATIONInstall the gasket with the protrusions in the position illustrated.
} B] INTAKE MANIFOLD INST ALLATIONTighten the nuts by the following procedure.
} C] FUEL PRESSURE REGU L ATOR/HIGH-PRESSURE FUEL HOSE INST ALL ATION
When connecting the fuel pressure regulator and the high- pressure fuel hose to the fuel rail, apply a small amount o new engine oil to the O-ring. Then insert the high-pressure fuel hose, being careful not to damage the O-ring.Ca uti on Be careful not to let any engine oil get into the fuel r a il .
} D] SURGE TANK GASKET INST ALL ATIONInstall the gasket with the protrusion in the position illustrated.Front
Protrusion
Fuel pressure regulator
Fuel rail
High-pressure fuel hose
Fuel rail
Order Mounting Nuts Tightening Torque
1 Right-bank nuts 7 Nm
2 Left-bank nuts 20 23 Nm
3 Right-bank nuts 20 23 Nm
4 Left-bank nuts 20 23 Nm5 Right-bank nuts 20 23 Nm
Right bank Left bank
Front
Intake manifold
Protrusion Front
Protrusion
-
8/11/2019 Manual Pajero 4x4 Intake and Exhaust
11/20
15-11INTAKE AND EXHAUST Intake Manifold
INSPECTION 15100370039Check the following points; replace the part if a problem is found.
INTAKE MANIFOLD CHE CK 1.2.
Check for damage or cracking of any part.Clogging of the negative pressure (vacuum) outlet port,or clogging of the gas passages.Check deflection of installation surface with straight edge and feeler gauge.Standard value: 0.15 mm or less
Limit: 0.20 mm
3.
-
8/11/2019 Manual Pajero 4x4 Intake and Exhaust
12/20
Turbocharger and Exh au st Manifold 15-12 INTAKE AND EXHAUST
TURBOCHARGER AND EXHAUS TREMOVAL AND INST ALLA TION
M ANI FO LD 15100450061
19 Nm 3
4 5 18 Nm 9 Nm 25 Nm 18 Nm
79 Nm
9 Nm 6
42 Nm 17 Nm
8 12118 Nm
14
10
112
9 Nm 30 Nm
9
13 43 Nm
15
Removal st ep s
1. Front exhaust pipe connection2. Boost hose3. Waste gate actuator4. Vacuum hose5. EGR valve6. EGR pipe7. Heat protector A8. Intake manifold
9. Heat protector10. Water pipe B11. Water pipe A12. Oil pipe13. Oil return hose connection14. Exhaust manifold and turbocharger
assembly15. Intake and exhaust manifold gasket
Pre-removal and Post-installation Oper at ion Engine Coolant Draining and Supplying Intercooler Removal and Installation (Refer to P. 15-5.) Air Cleaner Cover and Air Intake Hose Removal and
Installation (Refer to P. 15-4.)
-
8/11/2019 Manual Pajero 4x4 Intake and Exhaust
13/20
Turbocharger and Exh au st 15-13INT AKE AND EXHAUST Ma nif old
60 Nm
17
2216
2023
19
9 Nm 21
18 60 Nm
12 15 Nm
16. Exhaust fitting17. Exhaust fitting gasket18. Oil-return pipe19. Oil-return pipe gasket20. Exhaust manifold21. Turbocharger gasket
} A ] 22. Turbocharger assembly23. Heat protector
INST ALLA TION SERVICE POINT} A ] TURBOCHARGER ASSEMBLY INST ALL ATION1. Clean the alignment surfaces shown in the illustration.2. Supply clean engine oil from the oil pipe mounting hole
of the turbocharger assembly.Ca uti on When cleaning, take care that no foreign material g e t s into the engine coolant or oil passages ho le.
-
8/11/2019 Manual Pajero 4x4 Intake and Exhaust
14/20
Turbocharger and Exh au st INTAKE AND EXHAUST Manifold 15-14
INSPECTIONTURBOCHARGER ASSEMBLY CHEC K
15100640017
Visually check the turbine wheel and the compresso wheel for cracking or other damage.Check whether the turbine wheel and the compresso wheel can be easily turned by hand.Check for oil leakage from the turbocharger assembly.
Check whether or not the waste gate valve remains open. If any problem is found, replace the part after disassembly.
OIL PIPE AND OIL RETURN PIPE CHE CK 15100650010Check the oil pipe and oil return pipe for clogging, bending,or other damage. If there is clogging, clean it.
EXHAUST MANIFOLD CHE CK Damage or cracking of any part.
15100340108
Compressor wheel
-
8/11/2019 Manual Pajero 4x4 Intake and Exhaust
15/20
-
8/11/2019 Manual Pajero 4x4 Intake and Exhaust
16/20
15-16 INT AKE AND EXHAUST Tu r bocharg er
] B} TURBINE WHEEL ASSEMBLY REMOV AL Remove the turbine wheel assembly, striking thecircumference of the compressor cover with a plastic hammer The turbine wheel assembly may be a little hard to remov due to an O-ring put on the outer circumference.
CLEANING1. Use a clean cleaning oil commercially available. Do no
use corrosive cleaning oils as they could damage to some parts.
2. Use a plastic scraper or hard brush to clean aluminum parts.
REASSEMBLY SERVICE POINTS} A ] O-RING INST ALLATION
Apply a light coat of engine oil to a new O-ring and fit in the turbine wheel assembly groove.Ca uti on When installing the O-ring, use care not to damage i t .
A damaged O-ring causes oil leaks .
} B] TURBINE WHEEL A SSEM BLY1. Apply a light coat of engine oil to the periphery of the
O-ring.2. Install the turbine wheel assembly to the compressor cover
in relation to the dowel pin.Ca uti on Use care not to damage the blades of turbine wh ee l and compressor wh eel .
} C] SNAP RING INST ALLATIONLay the assembly with the compressor cover facing down and fit the snap ring.Ca uti on Fit the snap ring with its chamfered side facing up .
Snap ring edge Chamfered
Turbine wheel assembly
Compressor cover
Dowel pin hole
Dowel pin
O-ring
Turbine wheel as- sembly
-
8/11/2019 Manual Pajero 4x4 Intake and Exhaust
17/20
15-17INT AKE AND EXHAUST Tu r bocharg er
} D] TURBINE HOUSING INST ALLATIONInstall the turbine housing in relation to the dowel pin.Ca uti on Use care not to damage the blades of turbine wh ee l.
} E] COUPLING INST ALLATIONInstall the coupling and tighten to specified torque.
INSPECTIONTURBINE HOUSING1. Check the housing for traces of contact with the turbine
wheel, cracks due to overheating, pitching, deformation and other damage. Replace with a new turbine housing if cracked.
2. Operate the waste gate valve lever manually to chec that the gate can be operated and closed smoothly.
15100610018
COMPRESSOR COVERCheck the compressor cover for traces of contact with the compressor wheel and other damage.TURBINE WHEEL ASSEM BLY1. Check the turbine and compressor wheel blades for bend,
burr, damage, corrosion and traces of contact on the back side and replace if defective.Check the oil passage of the turbine wheel assemblyfor deposit and clogging.In the case of water cooled type, check also the wate passage for deposit and clogging.Check the turbine wheel and compressor wheel for ligh and smooth turning.
2.Compressor
3.
4.
OIL PIPE/OIL RETURN PIPECorrect or replace the oil pipe and oil return pipe if clogged,collapsed, deformed or otherwise damaged.
Oil passage
Turbine wheel
Water passage
wheel
Traces for contact
Coupling
Dower pin
Dower pin hole
-
8/11/2019 Manual Pajero 4x4 Intake and Exhaust
18/20
15-18 INTAKE AND EXHAUST E xhaust Mani f ol d
EXHAUST MANIFOLD 15100330587REMOV AL AND INST ALLA TION
112 15 Nm
42
18 Nm 44 Nm
59 Nm 344 Nm 5
7 6
12 15 Nm
Removal st ep s 1. Heat protector (R.H.)2. Exhaust manifold (R.H.)3. Exhaust manifold gasket (R.H.)4. EGR pipe
5. Heat protector (L.H.)6. Exhaust manifold (L.H.)7. Exhaust manifold gasket (L.H.)
INSPECTION 15100340160Check the following points; replace the part if a problem is found.EXHAUST MANIFOLD CHE CK 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
Pre-removal and Post-installation Oper at ion Front Exhaust Pipe Removal and Installation
(Refer to P.15-19.) Air Cleaner Removal and Installation
(Refer to P.15-4.)
Battery and Battery Tray Removal and Installation Engine Oil Dipstick Guide Removal and Installation
-
8/11/2019 Manual Pajero 4x4 Intake and Exhaust
19/20
15-19INTAKE AND EXHAUST E xhaust P ipe a nd Main Muffler
EXHAUST PIPE AND MAIN MUFFLE R 15100540461REMOV AL AND INST ALLA TION
1617
13 Nm 213 Nm 14 115
413 Nm 510 344 Nm 6
13 49 Nm 49 Nm
49 Nm 13 Nm 425 Nm 5
107 13
Nm 813 25 Nm 49 Nm
25 Nm
1617
13 Nm 211413 Nm 15
4 3513 Nm 25 Nm
49 Nm
25 Nm 13 Nm 45749 Nm 13 Nm 11 7849 Nm
Main muffler removal st ep s 1. Tail pipe2. Hanger3. Main muffler4. Hanger5. ProtectorCenter exhaust pipe removal s t e p s 6. Center exhaust pipe7. Hanger8. Protector
9. Catalytic converter Front exhaust pipe removal s t ep s
] A} } A ]
10.
Oxygen
sensor
11. Front exhaust pipe
12. Front exhaust pipe (R.H.) 13. Front exhaust pipe (L.H.) 14. Hanger15. Protector16. Front floor heat protector B17. Front floor heat protector A
Pre-removal and Post-installation Oper at ion Front Under Cover Removal and Installation
-
8/11/2019 Manual Pajero 4x4 Intake and Exhaust
20/20
15-20 INTAKE AND EXHAUST Exhaust Pipe and Main Muffler
REMOVAL SERVICE POINT] A} OXYGEN SENSOR REMOV A L Use special tool to remove the oxygen sensor.
INSTALLATION SERVICE POINT} A ] OXYGEN SENSOR INST ALL ATIONUse special tool to install the oxygen sensor.
MD998770