MITSUBISHI MONTERO 2000 Service Repair Manual

E
XH AUST PIP E AND MAIN MUFFLE R <4M 4>
R EM OVA L AND IN STA LLA TIO N 3
1
3
14
8
1 1
1
1 7 6
6
1 3
13
1
8
1 9
5 1
7
4 9
±4
N
×m
4
9
±1
0 N
×m
2 5
±4
N
×m 4
9
±1
0 N
×m 1
3
±2
N
×m
13
±2
N
×m
4
9
±1
0 N
×m
< L ong wheelb ase> 2
1 3 6
1 2
9 6
4
13
1
4
1
3
1 9 1
8
5
1
6
15 1
6

INTAKE AND EXHAUST -Exhaust Pipe and Main Muffler<4M4>15-26
Exhaust main muffler and rear
floor heat protector removal steps

1. Exhaust main muffler
6. Hanger
7. Hanger bracket
8. Hanger bracket
11. Rear floor heat protector
Tail exhaust pipe and rear floor
heat protector removal steps

2. Tail exhaust pipe
7. Hanger
9. Hanger bracket
10. Hanger bracket
12. Rear floor heat protector
Center exhaust pipe removal steps

3. Center exhaust pipe
13. Hanger
14. Hanger bracketExhaust main muffler removal steps

4. Exhaust main muffler
13. Hanger
14. Hanger bracket
Front exhaust pipe and dash heat
protector removal steps
DUnder cover
5. Front exhaust pipe
15. Exhaust support bracket
16. Dash heat protector
Front floor heat protector removal
steps
17. Catalytic converter
18. Front floor heat protector
19. Seal ring


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15-1
INTAKE AND
EXHAUST
CONTENTS
GENERAL 2.................................
Outline of Changes 2...........................
GENERAL INFORMATION 2..................
SERVICE SPECIFICATIONS 3.................
SEALANT 3..................................
ON-VEHICLE SERVICE 4.....................
Turbocharger Supercharging Check 4............
Supercharging Pressure Control
System Check 5...............................
Variable Geometry Actuator Check 6.............Variable Geometry Solenoid Valve Check 6.......
INTAKE MANIFOLD AND THROTTLE BODY
<4M4> 7.....................................
INTAKE MANIFOLD AND EXHAUST
MANIFOLD, THROTTLE BODY AND
TURBOCHARGER <4D5> 10..................
TURBOCHARGER AND EXHAUST
MANIFOLD <4M4> 12........................
EXHAUST PIPE AND MAIN MUFFLER
<4D5> 14....................................


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G
EN ER AL
O UTLIN E OF CHANG ES
S om e se rv ic e pro ce dure s have been esta blis h ed as th e fo llo w in g ch anges have been made due to th e
c o m plia nce wit h th e Em is sio n Regula tio n Ste p III.
D An oxyg en se nso r (re ar) has been added. Its se rv ic e pro ce dure is th e sa m e as fo r th e pre vio us
M T models <6G 7-A /T >.
D The tu rb och arg er has been ch anged to aVaria ble Geom etr y (V G ) ty p e <4D 5> .
D Aca ta ly tic co nve rte r has been added <4D 5> .
D The in ta ke manif o ld has been re sh aped <4M 4> .
D An EG R co ole r has been added <4M 4> .
D The va ria ble geom etr y tu rb och arg er ca n not be dis a sse m ble d, and must be alw ays re pla ce d as an
a sse m bly .
G EN ER AL IN FO RM ATIO N
T he va ria ble geom etr y so le noid va lv e is duty co ntr o lle d to co ntr o lth e va ria ble nozzle openin g angle of th e
v a ria ble geom etr y tu rb och arg er. T his allo w s to obta in th e ch ara cte ris tic of boost pre ssu re co rre sp ondin g to
t h e engin e opera tio n sta tu s.

INTAKE AND EXHAUST -General Information/Service Specifications/Sealant15-3
At starting and driving at low speed, the duty control
value of the variable geometry solenoid valve is
increased to apply the vacuum pressure of the
vacuum pump to the variable geometry actuator.
Applying the vacuum pressure to the variable
geometry actuator pulls the actuator rod so that
it can move towards the direction of closing the
variable nozzle of the variable geometry
turbocharger. As closing the nozzle reduces the
exhaust gas mass, the speed of exhaust gas flow
will be increased and efficiency will be improved.
Since the characteristic of boost pressure becomes
a low speed type, boost pressure will suddenly
rise from low speed.
At driving at high speed, the duty control value
of the variable geometry solenoid valve is
decreased to reduce the vacuum pressure from
the vacuum pump so that the actuator rod can
return to the deactivated status and move towards
the direction of opening the nozzle of the variable
geometry turbocharger.Opening the nozzle allows the characteristic of
boost pressure to become a high speed type so
that the appropriate boost pressure can be
maintained.
Therefore, boost pressure can be controlled by
appropriate duty control of the variable geometry
solenoid valve. The engine-ECU calculates the
correct boost pressure based on the engine speed
and fuel injection amount. Furthermore, the duty
control of the variable geometry solenoid valve is
given feedback of the signals from the variable
geometry control pressure sensor and the boost
pressure sensor so that the variable nozzle opening
angle of the variable geometry turbocharger can
be quickly adjusted to obtain the desired boost
pressure.
SERVICE SPECIFICATIONS
ItemsStandard value
Variable geometry actuator activation vacuum
(Approximately 1 mm stroke) kPaApproximately 10.5 - 12.5
Variable geometry solenoid valve coil resistance
(at 20°C)Ω29 - 35
SEALANT
ItemSpecified sealantRemarks
Thread of the intake manifold mounting
bolts3M Stud Locking No.4170 or equivalentAnaerobic sealant


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O
N-V EH IC LE SER VIC E
T U RBO CHARG ER SU PER CHARG IN G CHEC K
C au tio n
C onduct th e driv in g te st in alo catio n where driv in g at
f u ll accele ra tio n can be done wit h safe ty . Tw o pers o n
s h ould be in th e veh ic le when th e te st is co nducte d ; th e
p ers o n in th e passen ger seat sh ould re ad th e in dic atio ns
s h ow n by th e MUT-I I.
1 . Set th e ve hic le to th e pre -in sp ectio n co ndit io n.
2 . Turn th e ig nit io n sw it c h to “L O CK” (O FF) posit io n, and
c o nnect th e dia gnosis co nnecto r to th e MUT-II .
3 . Use th e data lis t fu nctio n nam ed “Ite m No. 04” boost
p re ssu re se nso r ofth e M UT-II to ch eck th e su perc h arg in g
p re ssu re when th e engin e sp eed in cre ase s to
a ppro xim ate ly 3,0 00 r/m in or more by driv in g at fu ll
a cce le ra tio n in 2nd.
4 . When th e in dic a te d su perc h arg er does not beco m e
p osit iv e pre ssu re , ch eck th e fo llo w in g it e m s.
D Malf u nctio n of th e boost pre ssu re se nso r
D Leaka ge of su perc h arg in g pre ssu re
D Malf u nctio n of th e tu rb och arg er
5 . When th e in dic a te d su perc h arg er is 133 kP a or m ore ,
s u perc h arg in g co ntr o l m ay be fa ult y , th ere fo re ch eck th e
f o llo w in gs.
D Malf u nctio n of th e va ria ble geom etr y actu ato r
D Malf u nctio n of th e va ria ble nozzle
D Malf u nctio n of th e va ria ble geom etr y so le noid va lv e
D Malf u nctio n of th e boost pre ssu re se nso r
D Malf u nctio n of th e va ria ble geom etr y co ntr o lp re ssu re
s e nso r

V
aria ble geom etr y
a ctu ato r va cu um S
uperc h arg in g
p re ssu re O
FF 0
kP a A
ppro xim ate ly -1
k P a O
N A
ppro xim ate ly 80
k P a A
ppro xim ate ly 3
k P a

N
ip ple co ndit io n N
orm alc o ndit io n A
pplie d B
oth nip ple s are
o pened. V
acu um le aks. N
ip ple A is clo se d. V
acu um is m ain ta in ed. N
ota pplie d B
oth nip ple s are
o pened. V
acu um le aks. N
ip ple C is clo se d. V
acu um is m ain ta in ed. B
atte ry B
C A

I
N TA KE MANIF O LD AND TH RO TTLE BO DY <4M 4>
R EM OVA L AND IN STA LLA TIO N (
E ngin e oil)
2 3
4 5
6 7 8
9 1
0 1
2
1
3
2 4 2
2
14
1
5 1
6
1
7
1
8
19
2 3 ±1 N·m
29 ±1 N·m 2
2 ±4 N·m
4 4 ±8 N·m (
T ra nsm is sio n flu id ) 2
0
2 1 1
25
2
6 2
7 2
8
1 3 ±1 N·m 1
8 ±2 N·m
1 5 ±1 N·m
23 2
9
3.0 ±0.3 N·m
3.0 ±0.3 N·m
2 3
2
3
3
.0 ±0.3 N·m
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