Mitsubishi Outlander (2003+). Manual — part 132

INTAKE MANIFOLD

INTAKE AND EXHAUST

15-7

REMOVAL AND INSTALLATION <4G69>

M1151003000880

Pre-removal Operation

•

Fuel Line Pressure Reduction [Refer to GROUP 13B,

On-vehicle Service

−

Fuel Pump Connector

Disconnection (How to Reduce Pressurized Fuel Lines)

P.13B-428

].

•

Engine Coolant Draining (Refer to GROUP 14, On-vehicle

Service

−

Engine Coolant Replacement

P.14-17

).

•

Air Cleaner Cover and Air Intake Hose Removal (Refer to

P.15-4

).

•

Throttle Body Removal (Refer to GROUP 13B, Throttle

Body

P.13B-438

).

•

Delivery Pipe and Injector Assembly Removal (Refer to

GROUP 13B, Injector

P.13B-437

).

Post-installation Operation

•

Delivery Pipe and Injector Assembly Installation (Refer to

GROUP 13B, Injector

P.13B-437

).

•

Throttle Body Installation (Refer to GROUP 13B, Throttle

Body

P.13B-438

).

•

Air Cleaner Cover and Air Intake Hose Installation (Refer

to

P.15-4

).

•

Engine Coolant Refilling (Refer to GROUP 14, On-vehicle

Service

−

Engine Coolant Replacement

P.14-17

).

AC309416

<R.H. drive vehicle>

<L.H. drive vehicle>

4

4

6

6

5

5

3

3

8

29 12

10

13

23

9

24

7

14

15

16

25

26

28

22

1

2

19

20

21

17

18

24 ± 4 N·m

24 ± 3 N·m

20 ± 2 N·m

24 ± 3 N·m

5.0 ± 1.0 N·m

11 ± 1 N·m

11 ± 1 N·m

13 ± 1 N·m

31 ± 3 N·m

N

N

N

(Engine oil)

AB

27

N

11

Removal steps

1. EGR valve

>>C<<

2. EGR valve gasket
3. Capacitor connector
4. Brake booster vacuum hose
5. Capacitor

6. Brake booster vacuum pipe
7. Brake booster vacuum hose
8. Evaporative emission vacuum hose

connection

Removal steps (Continued)

INTAKE MANIFOLD

INTAKE AND EXHAUST

15-8

REMOVAL SERVICE POINT

<<A>> RADIATOR LOWER HOSE
DISCONNECTION

Make mating marks on the radiator hose and the
hose clamp. Disconnect the radiator hose.

INSTALLATION SERVICE POINTS

>>A<< THERMOSTAT CASE ASSEMBLY
INSTALLATION
1. Use a gasket scraper or wire brush to completely

eliminate all gasket material on the gasket
mounting surface.

2. Apply a bead of the sealant to the cylinder head

mating surface of the thermostat case assembly
as shown.

Specified Sealant: MITSUBISHI GENUINE
PART No.MD970389 or equivalent

3. Apply sealant to the thread of the thermostat case

assembly bolts as shown.

Specified Sealant: 3M Stud Locking 4170 or
equivalent

4. With the sealant still wet (within 15 minutes after

the sealant is applied), install the thermostat case
assembly. Do not apply the sealant in an area
more than the required.

9. Manifold absolute pressure sensor

connector

10. Detonation sensor connector
11. Evaporative emission purge solenoid

valve connector

12. Harness clamp
13. Detonation sensor connector clamp
14. Harness clamp
15. Oil level gauge and guide
16. O-ring
17. Harness clamp

<<A>> >>B<<

18. Radiator lower hose connection
19. Heater water hose connection
20. Engine coolant temperature gauge

unit connector

>>A<<

21. Thermostat housing assembly
22. O-ring
23. Detonation sensor harness clamp
24. Manifold absolute pressure sensor
25. Harness clamp
26. Intake manifold stay
27. Intake manifold
28. Intake manifold gasket
29. Evaporative emission purge solenoid

valve, evaporative emission vacuum
hose and pipe assembly

Removal steps (Continued)

AC200641AC

Mating marks

AC305212

Thermostat case assembly

Ø3 mm

AD

AC303724AE

Thermostat case assembly

INTAKE MANIFOLD

INTAKE AND EXHAUST

15-9

>>B<< RADIATOR LOWER HOSE CONNECTION

1. Insert each hose as far as the projection of the

water inlet fitting.

2. Align the mating marks on the radiator hose and

hose clamp, and then connect the radiator hose.

>>C<< EGR VALVE GASKET INSTALLATION

Install the EGR valve gasket as shown in the
illustration.

INSPECTION

M1151003100553

Check the following points; replace the part if a
problem is found.
Intake Manifold Check
1. Check for damage or cracking of any part.
2. Clogging of the negative pressure (vacuum) outlet

port, or clogging of the exhaust gas recirculation
passages.

3. Using a straight edge and feeler gauge, check for

distortion of the cylinder head installation surface.
Standard value: 0.15 mm or less
Limit: 0.20 mm

AC200642

Mating marks

Projection

Water inlet fitting

AE

AC302358AE

Gasket

Notched
part

Notched
part

EXHAUST MANIFOLD

INTAKE AND EXHAUST

15-10

EXHAUST MANIFOLD

REMOVAL AND INSTALLATION <4G63>

M1151003300717

REMOVAL SERVICE POINT

<<A>> OXYGEN SENSOR REMOVAL

Use special tool oxygen sensor wrench (MD998770)
to remove the oxygen sensor.

INSTALLATION SERVICE POINT

>>A<< OXYGEN SENSOR INSTALLATION

Use special tool oxygen sensor wrench (MD998770)
to install the oxygen sensor.

AC301312

49 ± 10 N·m

44 ± 5 N·m

35 ± 6 N·m

14 ± 1 N·m

14 ± 1 N·m

49 ± 5 N·m

29 ± 3 N·m

29 ± 3 N·m

N

1

2

3

4

5

N

6

7

44 ± 5 N·m

AB

8

Removal steps

<<A>> >>A<<

1. Oxygen sensor
2. Exhaust manifold cover
3. Front exhaust pipe connection
4. Exhaust pipe gasket
5. Exhaust manifold bracket
6. Engine hanger
7. Exhaust manifold
8. Exhaust manifold gasket

AC212566AB

MD998770

Oxygen sensor

AC212566AB

MD998770

Oxygen sensor