Mitsubishi L200. Manual — part 216

EXHAUST MANIFOLD AND TURBOCHARGER

INTAKE AND EXHAUST

15-19

EXHAUST MANIFOLD AND TURBOCHARGER

REMOVAL AND INSTALLATION <Except Euro5>

M1151008901353

Pre-removal Operation
• Under Skid Plate and Engine Room Under Cover

Removal (Refer to GROUP 51

− Under Cover ).

• Engine Coolant Draining (Refer to GROUP 14 − On-vehi-

cle Service, Engine Coolant Replacement ).

• Air Cleaner Assembly Removal (Refer to

P.15-6

).

• Battery and Battery Box Removal (Refer to GROUP 54A

− Battery ).

• Intercooler Inlet Air Hose Removal (Refer to

P.15-8

).

• Catalytic Converter Removal (Refer to GROUP 17 − Cat-

alytic Converter ).

Post-installation Operation
• Catalytic Converter Installation (Refer to GROUP 17 −

Catalytic Converter ).

• Intercooler Inlet Air Hose Installation (Refer to

P.15-8

).

• Battery and Battery Box Installation (Refer to GROUP

54A

− Battery ).

• Air Cleaner Assembly Installation (Refer to

P.15-6

).

• Under Skid Plate and Engine Room Under Cover Installa-

tion (Refer to GROUP 51

− Under Cover ).

• Engine Coolant Refilling (Refer to GROUP 14 − On-vehi-

cle Service, Engine Coolant Replacement ).

AC804075

7

AC

9

11

N

17

11 ± 1 N·m

53 ± 7 N·m

8

N

6

59 ± 10 N·m

17 ± 2 N·m

2

N

1

9.0 ± 1.0 N·m

17 ± 2 N·m

2

N

11 ± 1 N·m

3

4

15

14 ± 1 N·m

13

14

N

5

N

30 ± 2 N·m

18 ± 2 N·m

53 ± 7 N·m

20

N

19

30 ± 2 N·m

18 ± 2 N·m

9.0 ± 1.0 N·m

9.0 ± 1.0 N·m

10

N

12

N

18

N

18

N

18

N

16

N

Removal steps

1.

Turbocharger oil feed pipe

2.

Turbocharger oil feed pipe gasket

3.

Turbocharger water return hose
connection

4.

Turbocharger water feed pipe

5.

Turbocharger water feed pipe
gasket

6.

Turbocharger water feed hose
connection

7.

Turbocharger water return pipe

8.

Turbocharger water return pipe
gasket

9.

Turbocharger oil return pipe

10. Turbocharger oil return pipe

gasket

Removal steps (Continued)

EXHAUST MANIFOLD AND TURBOCHARGER

INTAKE AND EXHAUST

15-20

REMOVAL SERVICE POINT

<<A>> OIL PIPE REMOVAL

CAUTION

Take care not to allow foreign objects to get into
the oil passage hole of the turbocharger assem-
bly after the oil pipe is removed.

INSTALLATION SERVICE POINTS

>>A<< TURBOCHARGER GASKET INSTALLA-
TION

AC502995AB

Section A-A

Projection

A

A

Position the projection as shown in the illustration.

>>B<< TURBOCHARGER ASSEMBLY
INSTALLATION
1. Check the internal surface, the eye bolt and the

mating surface of the oil pipe and water pipe for
clogging, and clean if necessary.

CAUTION

Be careful not to allow foreign material to enter
the turbocharger.
2. If deposits of carbon are accumulated on the

turbocharger oil passage, remove them and clean
using the compressed air.

3. Add clean engine oil through the oil feed pipe port

on the turbocharger.

>>C<< OIL RETURN PIPE GASKET
INSTALLATION

AC502996AB

Projection

Oil return
pipe

Position the projection as shown in the illustration.

>>

C

<<

11. Turbocharger oil return pipe

gasket

12. Nut and washer

>>

B

<<

13. Turbocharger assembly

>>

A

<<

14. Turbocharger gasket
15. Exhaust manifold cover
16. Flange nut
17. Engine hanger
18. Nut and washer
19. Exhaust manifold
20. Exhaust manifold gasket

Removal steps (Continued)

EXHAUST MANIFOLD AND TURBOCHARGER

INTAKE AND EXHAUST

15-21

REMOVAL AND INSTALLATION <Euro5>

M1151008901364

Pre-removal Operation
• Under Skid Plate and Engine Room Under Cover

Removal (Refer to GROUP 51

− Under Cover ).

• Engine Coolant Draining (Refer to GROUP 14 − On-vehi-

cle Service, Engine Coolant Replacement ).

• Air Cleaner Assembly Removal (Refer to

P.15-6

).

• Battery and Battery Box Removal (Refer to GROUP 54A

− Battery ).

• Intercooler Inlet Air Hose Removal (Refer to

P.15-12

).

• Catalytic Converter Removal (Refer to GROUP 17 − Cat-

alytic Converter ).

Post-installation Operation
• Catalytic Converter Installation (Refer to GROUP 17 −

Catalytic Converter ).

• Intercooler Inlet Air Hose Installation (Refer to

P.15-12

).

• Battery and Battery Box Installation (Refer to GROUP

54A

− Battery ).

• Air Cleaner Assembly Installation (Refer to

P.15-6

).

• Under Skid Plate and Engine Room Under Cover Installa-

tion (Refer to GROUP 51

− Under Cover ).

• Engine Coolant Refilling (Refer to GROUP 14 − On-vehi-

cle Service, Engine Coolant Replacement ).

AC900935AC

10

16

2

5

7

9

17

17 ± 2 N·m

19

20

N

4

N

1

6

34 ± 3 N·m

62 ± 5 N·m

59 ± 10 N·m

13

8

14

N

3.0 ± 0.5 N·m

9.0 ± 1.0 N·m

17 ± 2 N·m

4

N

62 ± 5 N·m

14 ± 1 N·m

3

9.0 ± 1.0 N·m

24 ± 3 N·m

59 ± 10 N·m

15

14 ± 1 N·m

34 ± 3 N·m

24 ± 3 N·m

14 ± 1 N·m

11

N

18

N

18

N

18

N

12

N

Removal steps

1.

Engine cover

2.

Turbocharger heat protector

<<

A

>>

3.

Oil pipe

4.

Gasket

5.

Heat protector

6.

Heat protector bracket

7.

Water hose connection

8.

Water hose connection

9.

Oil return hose

10. Vacuum hose connection
11. Nut and washer
12. Bolt and washer
13. Turbocharger, turbocharger water

pipe and oil return pipe assembly

Removal steps (Continued)

EXHAUST MANIFOLD AND TURBOCHARGER

INTAKE AND EXHAUST

15-22

REMOVAL SERVICE POINT

<<A>> OIL PIPE REMOVAL

CAUTION

Take care not to allow foreign objects to get into
the oil passage hole of the turbocharger assem-
bly after the oil pipe is removed.

INSTALLATION SERVICE POINTS

>>A<< TURBOCHARGER ASSEMBLY INSTALLA-
TION
1. Check the internal surface, the eye bolt and the

mating surface of the oil pipe and water pipe for
clogging, and clean if necessary.

CAUTION

Be careful not to allow foreign material to enter
the turbocharger.
2. If deposits of carbon are accumulated on the

turbocharger oil passage, remove them and clean
using the compressed air.

3. Add clean engine oil through the oil pipe port on

the turbocharger.

>>B<< TURBOCHARGER WATER PIPE GASKET
INSTALLATION

AC805773 AB

Projection

Turbocharger
water pipe

Turbocharger
water pipe
gasket

Turbocharger
assembly

>>

D

<<

14. Turbocharger gasket
15. Exhaust manifold heat protector A
16. Exhaust manifold heat protector B
17. Engine hanger
18. Nut and washer
19. Exhaust manifold
20. Exhaust manifold gasket

AC805771

11 ± 1 N·m

9.0 ± 1.0 N·m

21

22

23

26

N

AC

24

25

N

24 ± 3 N·m

Removal steps

21. Oil return pipe

>>

C

<<

22. Oil return pipe gasket
23. Water hose
24. Turbocharger water pipe

>>

B

<<

25. Turbocharger water pipe gasket

>>

A

<<

26. Turbocharger assembly

Removal steps (Continued)