Mitsubishi Car 1999-05

Turbocharger

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Removal & Installation



2.0L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine oil, cooling system and remove the radiator. On vehicles equipped with A/C, remove the condenser fan assembly with the radiator.
  4.  
  5. Disconnect the oxygen sensor connector and remove the sensor.
  6.  
  7. Remove the oil dipstick and tube.
  8.  
  9. Remove the air intake bellows hose, the wastegate vacuum hose, the connections for the air outlet hose, and the upper and lower heat shield.
  10.  
  11. Unbolt the power steering pump and bracket assembly and leaving the hoses connected, wire it aside.
  12.  
  13. Remove the self-locking exhaust manifold nuts, the triangular engine hanger bracket, the eyebolt and gaskets that connect the oil feed line to the turbo center section and the water cooling lines. The water line under the turbo has a threaded connection.
  14.  
  15. Remove the exhaust pipe nuts and gasket and lift off the exhaust manifold. Discard the gasket.
  16.  
  17. Remove the 2 through bolts and 2 nuts that hold the exhaust manifold to the turbocharger.
  18.  
  19. Remove the 2 cap screws from the oil return line (under the turbo). Discard the gasket. Separate the turbo from the exhaust manifold. The 2 water pipes and oil feed line can still be attached.
  20.  
  21. Visually check the turbine wheel (hot side) and compressor wheel (cold side) for cracking or other damage. Check whether the turbine wheel and the compressor wheel can be easily turned by hand. Check for oil leakage. Check whether or not the wastegate valve remains open. If any problem is found, replace the part. Inspect oil passages for restriction or deposits and clean as required.
  22.  
  23. The wastegate can be checked with a pressure tester. Apply approximately 9 psi to the actuator and make sure the rod moves. Do not apply more than 10.3 psi or the diaphragm in the wastegate may be damaged. Vacuum applied to the wastegate actuator should be maintained, replace if leaks vacuum. Do not attempt to adjust the wastegate valve.

    Click image to see an enlarged view

    Fig. Exploded view of the turbocharger assembly-1999 2.0L Engine

  24.  

To install:

  1. Prime the oil return line with clean engine oil. Replace all locking nuts. Before installing the threaded connection for the water inlet pipe, apply light oil to the inner surface of the pipe flange. Assemble the turbocharger and exhaust manifold.
  2.  
  3. Install the exhaust manifold using a new gasket.
  4.  
  5. Connect the water cooling lines, oil feed line and engine hanger.
  6.  
  7. If removed, install the power steering pump and bracket.
  8.  
  9. Install the heat shields, air outlet hose, wastegate hose and air intake bellows.
  10.  
  11. Install the oil dipstick tube and dipstick. Install the oxygen sensor.
  12.  
  13. Install the radiator assembly.
  14.  
  15. Fill the engine with oil, fill the cooling system and reconnect the negative battery cable.
  16.  

Evolution

CAUTION
The air bag system must be disarmed before removing the turbocharger.

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine coolant.
  4.  
  5. Disengage the retaining clips and remove the front under cover, located under the front of the vehicle behind the front bumper face.
  6.  
  7. Remove the radiator assembly.
  8.  
  9. Remove the air intake hose from the air cleaner assembly.
  10.  
  11. Remove the air pipes & hoses from the charge air cooler assembly.
  12.  
  13. Remove the front axle crossmember bar from underneath the vehicle.

    Click image to see an enlarged view

    Fig. Front axle crossmember assembly-Evolution

  14.  
  15. Remove the front exhaust pipe from the exhaust manifold.
  16.  
  17. Remove the exhaust manifold cover.
  18.  
  19. Remove the front Heated Oxygen (HO 2 S) sensor.
  20.  
  21. Remove the turbocharger heat protector.
  22.  
  23. Disconnect the turbocharger water feed pipe and return hose connections and remove gaskets.
  24.  
  25. Disconnect the turbocharger oil feed and oil return pipes and remove gaskets.
  26.  
  27. Remove the starter motor.
  28.  
  29. Disconnect the vacuum hose connections.
  30.  
  31. Remove the air outlet fitting and gasket.
  32.  
  33. Remove the exhaust fitting bracket.
  34.  
  35. Remove the turbocharger and exhaust fitting assembly. Remove the gasket.
  36.  
  37. Remove the exhaust manifold and gasket.
  38.  

To install:

  1. Clean all gasket material from the mating surfaces.
  2.  
  3. Install a new gasket and exhaust manifold. Tighten the retainers to 32-40 ft. lbs. (44-54 Nm).
  4.  
  5. Install the turbocharger assembly. Be sure to clean the oil and water pipe fittings, inside of eye bolts and individual pipes of any clogs. Clean or use compressed air to remove any carbon matter stuck in the oil passage of the turbocharger. Refill new engine oil at the oil feed pipe fitting hole.
  6.  
  7. Install the exhaust fitting assembly, along with a new gasket.
  8.  
  9. Install the exhaust fitting bracket.
  10.  
  11. Install the air outlet fitting and gasket.
  12.  
  13. Connect the vacuum hose connections.
  14.  
  15. Install the starter motor.
  16.  
  17. Connect the turbocharger oil feed and oil return pipes, along with new gaskets. Tighten the oil feed pipe fastener to 10-14 ft. lbs. (15-19 Nm). Tighten the oil return pipe fasteners to 71-89 inch lbs. (8-10 Nm).
  18.  
  19. Connect the turbocharger water feed pipe and return hoses, along with new gaskets. Tighten the pipe fasteners to 26-36 ft. lbs. (35-49 Nm).
  20.  
  21. Install the turbocharger heat protector.
  22.  
  23. Install the front Heated Oxygen (HO 2 S) sensor.
  24.  
  25. Install the exhaust manifold cover.
  26.  
  27. Install the front exhaust pipe to the exhaust manifold.
  28.  
  29. Install the front axle crossmember bar from underneath the vehicle.
  30.  
  31. Install the air pipes & hoses to the charge air cooler assembly.
  32.  
  33. Install the air intake hose to the air cleaner assembly.
  34.  
  35. Install the radiator assembly.
  36.  
  37. Install the front under cover and secure with the retaining clips.
  38.  
  39. Refill the cooling system with the correct amount and type of coolant.
  40.  
  41. Connect the negative battery cable.

    Click image to see an enlarged view

    Fig. Turbocharger and exhaust manifold assembly-Evolution

  42.  

Left Side (Rear)
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the battery.
  4.  
  5. Drain the coolant.
  6.  
  7. Remove the front exhaust pipe.
  8.  
  9. Disconnect the accelerator cable from the throttle body.
  10.  
  11. Remove the intake air hose, the air pipe across the top of the engine and its heat shield.
  12.  
  13. Remove the clutch booster vacuum hose and disconnect the accelerator cable from the pedal.
  14.  
  15. Remove the air intake hoses coming from the air cleaner box.
  16.  
  17. Remove the Heated Oxygen (HO 2 S) sensor and the turbocharger heat shield.
  18.  
  19. Remove the Exhaust Gas Recirculation (EGR) pipe, if equipped.
  20.  
  21. Remove the oil feed pipe.
  22.  
  23. Remove the EGR valve, if equipped.
  24.  
  25. Remove the water feed pipes.
  26.  
  27. Remove the exhaust extension fitting and bracket.
  28.  
  29. Remove the inner heat shield.
  30.  
  31. Remove the oil return tube.
  32.  
  33. Remove the turbocharger to exhaust manifold nuts and remove the turbocharger assembly.
  34.  

To install:

  1. Clean all mating surfaces. Pour clean engine oil through the oil pipe feed hole in the turbocharger.
  2.  
  3. Install a new gasket and ring and install the turbocharger to the manifold. Torque the nuts to 40-47 ft. lbs. (55-65 Nm).
  4.  
  5. Install the oil return line.
  6.  
  7. Install the inner heat shield.
  8.  
  9. Install the exhaust extension fitting and bracket. Torque the nuts to 40-47 ft. lbs. (55-65 Nm).
  10.  
  11. Install the water feed pipes.
  12.  
  13. Install the EGR valve, if equipped.
  14.  
  15. Install the oil feed pipe.
  16.  
  17. Install the EGR pipe, if equipped.
  18.  
  19. Install the turbocharger heat shield and HO 2 S sensor.
  20.  
  21. Install the air intake hoses coming from the air cleaner box. Be sure the triangular aligning marks are engaged.
  22.  
  23. Install the clutch booster vacuum hose.
  24.  
  25. Install the heat shield, the air pipe across the top of the engine and the air intake hose.
  26.  
  27. Connect the accelerator cable to the throttle body.
  28.  
  29. Connect the front exhaust pipe.
  30.  
  31. Fill the system with coolant.
  32.  
  33. Install the battery.
  34.  

Right Side (Front)
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the radiator.
  6.  
  7. Remove the right side transaxle bracket.
  8.  
  9. Remove the front exhaust pipe.
  10.  
  11. Remove all air intake hoses and pipes along the front of the engine.
  12.  
  13. Remove the alternator.
  14.  
  15. Remove the oil dipstick tube.
  16.  
  17. Remove the turbocharger heat shield.
  18.  
  19. Remove the water feed pipes.
  20.  
  21. Remove the Heated Oxygen (HO 2 S) sensor.
  22.  
  23. Remove the oil return line.
  24.  
  25. Remove the exhaust extension fitting and bracket.
  26.  
  27. Remove all air conditioning components preventing removal of the turbocharger.
  28.  
  29. Remove the oil feed tube.
  30.  
  31. Remove the turbocharger to exhaust manifold bolts and remove the turbocharger assembly.
  32.  

To install:

  1. Clean all mating surfaces. Pour clean engine oil through the oil pipe feed hole in the turbocharger.
  2.  
  3. Install a new gasket and ring and install the turbocharger to the manifold. Torque the bolts to 40-47 ft. lbs. (55-65 Nm).
  4.  
  5. Install the oil feed pipe.
  6.  
  7. Install the removed air conditioning components.
  8.  
  9. Install the exhaust extension fitting and bracket. Torque the nuts to 40-47 ft. lbs. (55-65 Nm).
  10.  
  11. Install the oil return line.
  12.  
  13. Install the HO 2 S sensor.
  14.  
  15. Install the water feed pipes.
  16.  
  17. Install the turbocharger heat shield.
  18.  
  19. Install the dipstick tube.
  20.  
  21. Install the alternator.
  22.  
  23. Install all air intake hoses and pipes along the front of the engine.
  24.  
  25. Install a new gasket and connect the front exhaust pipe.
  26.  
  27. Install the right side transaxle bracket.
  28.  
  29. Install the radiator.
  30.  
  31. Fill the system with coolant.
  32.  
  33. Connect the negative battery cable.
  34.  

 
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