Mitsubishi Eclipse / Eclipse Spyder (2000-2002). Service and repair manual — part 350

15-1

GROUP 15

INTAKE AND

EXHAUST

CONTENTS

GENERAL DESCRIPTION. . . . . . . . .

15-2

INTAKE AND EXHAUST DIAGNOSIS

15-2

INTRODUCTION TO INTAKE AND EXHAUST
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . .

15-2

TROUBLESHOOTING STRATEGY . . . . . .

15-2

SYMPTOM CHART. . . . . . . . . . . . . . . . . . .

15-2

SYMPTOM PROCEDURES . . . . . . . . . . . .

15-3

SPECIAL TOOL . . . . . . . . . . . . . . . . .

15-4

ON-VEHICLE SERVICE. . . . . . . . . . .

15-4

INTAKE MANIFOLD VACUUM CHECK . . .

15-4

AIR CLEANER . . . . . . . . . . . . . . . . . .

15-5

REMOVAL AND INSTALLATION . . . . . . . .

15-5

INTAKE MANIFOLD PLENUM . . . . .

15-6

REMOVAL AND INSTALLATION . . . . . . . .

15-6

INTAKE MANIFOLD <2.4L> . . . . . . .

15-8

REMOVAL AND INSTALLATION . . . . . . . .

15-8

INSPECTION . . . . . . . . . . . . . . . . . . . . . . .

15-11

INTAKE MANIFOLD <3.0L>. . . . . . . .

15-12

REMOVAL AND INSTALLATION . . . . . . . .

15-12

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

15-14

EXHAUST MANIFOLD <2.4L> . . . . . .

15-15

REMOVAL AND INSTALLATION . . . . . . . .

15-15

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

15-16

EXHAUST MANIFOLD <3.0L> . . . . . .

15-17

REMOVAL AND INSTALLATION . . . . . . . .

15-17

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

15-18

EXHAUST PIPE, MAIN MUFFLER AND
CATALYTIC CONVERTER <2.4L> . .

15-19

REMOVAL AND INSTALLATION . . . . . . . .

15-19

EXHAUST PIPE, MAIN MUFFLER AND
CATALYTIC CONVERTER <3.0L> . .

15-21

REMOVAL AND INSTALLATION . . . . . . . .

15-21

SPECIFICATIONS . . . . . . . . . . . . . . .

15-22

FASTENER TIGHTENING
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . .

15-22

SERVICE SPECIFICATION . . . . . . . . . . . .

15-24

GENERAL DESCRIPTION

TSB Revision

INTAKE AND EXHAUST

15-2

.

G EN ER A L DESC RIPTIO N

M1151000100134

The exhaust pipe is divided into five <3.0L Engine>
or four <2.4L Engine> parts.

IN TA K E A N D EXH A U ST D IA G N O SIS

INTRODUCTION TO INTAKE AND EXHAUST DIAGNOSIS

M1151006900105

The occurrence of exhaust leakage or abnormal
noise is caused by cracks or strain in the gasket, or
by when the exhaust pipe or muffler is damaged due
to impacts during travel. The exhaust leaks from
these sections and causes the exhaust noise to
increase. There may be cases when there is
interference with the body and vibration noise is
generated.

TROUBLESHOOTING STRATEGY

M1151007000105

Use these steps to plan your diagnostic strategy. If
you follow them carefully, you will be sure that you
have exhausted most of the possible ways to find an
intake or exhaust fault.
1. Gather information from the customer.

2. Verify that the condition described by the

customer exists.

3. Find the malfunction by following the SYMPTOM

CHART.

4. Verify malfunction is eliminated.

SYMPTOM CHART

M1151007100102

SYMPTOMS

INSPECTION PROCEDURE

REFERENCE PAGE

Exhaust leakage

1

P.15-3

Abnormal noise generation

2

P.15-3

INTAKE AND EXHAUST DIAGNOSIS

TSB Revision

INTAKE AND EXHAUST

15-3

SYMPTOM PROCEDURES

M1151007300054

INSPECTION PROCEDURE 1: Exhaust Leakage

DIAGNOSIS

STEP 1. Check the gasket for cracks damage.

Q: Is the gasket damaged?

YES :

Replace the gasket, then go Step 3.

NO :

Go to Step 2.

STEP 2. Check for loosening in each coupling
section.

Q: Is there any loosening in each section?

YES :

Tighten, then go to Step 3.

NO :

There is no action to be taken.

STEP 3. Check symptom.

Q: Is the exhaust leaking?

YES :

Return to Step 1.

NO :

This diagnosis is complete.

M1151007400040

INSPECTION PROCEDURE 2: Abnormal Noise

DIAGNOSIS

STEP 1. Check for missing parts in the muffler.
Tap the muffler lightly to check for loose baffles,
etc.

Q: Are there any missing parts in the muffler?

YES :

Replace, then go to Step 6.

NO :

Go to Step 2.

STEP 2. Check the hanger for cracks.

Q: Is the hanger cracked?

YES :

Replace, then go to Step 6.

NO :

Go to Step 3.

STEP 3. Check for interference of the pipes and
muffler with the body.

Q: Are the pipes and muffler interfering with the

body?
YES :

Repair, then go to Step 6.

NO :

Go to Step 4.

STEP 4. Check the heat protectors.

Q: Are any heat protectors loose or damaged?

YES :

Tighten or replace, then go to Step 6.

NO :

Go to Step 5.

STEP 5. Check the pipes, catalytic converters
and muffler for damage.

Q: Are the pipes, catalytic converters and muffler

damaged?
YES :

Replace, then go to Step 6.

(For the removal of the catalytic converter,
refer to GROUP 17

P.17-105

.)

NO :

There is no action to be taken.

STEP 6. Check symptom.

Q: Is any abnormal noise generated?

YES :

Return to Step 1.

NO :

This diagnosis is complete.

SPECIAL TOOL

TSB Revision

INTAKE AND EXHAUST

15-4

SPEC IA L TO O L

M1151000600106

O N -VEH IC LE SERVIC E

INTAKE MANIFOLD VACUUM CHECK

M1151001800062

<2.4L ENGINE>

Refer to GROUP 11A, On-vehicle Service

P.11A-9

.

<3.0L ENGINE>

Refer to GROUP 11C, On-vehicle Service

P.11C-9

.

TOOL

TOOL NUMBER AND
NAME

SUPERSESSION

APPLICATION

MD998770
Oxygen sensor wrench

MD998770-01 or general
service tool

Heated oxygen sensor
removal and installation

MD998770