Mitsubishi Montero Sport (2004+). Manual — part 589

INTAKE MANIFOLD

TSB Revision

INTAKE AND EXHAUST

15-5

INTAKE MANIFOLD

REMOVAL AND INSTALLATION

M1151003000857

Pre-removal and Post-installation Operation
• Throttle Body Removal and Installation (Refer to GROUP

13A, Throttle Body

P.13A-902

).

AC004649

4.9 N·m
43 in-lb

8.8 N·m
78 in-lb

8.8 N·m
78 in-lb

22 N·m
16 ft-lb

18 N·m
13 ft-lb

10 - 12 N·m
89 - 106 in-lb

10 - 12 N·m
89 - 106 in-lb

17 - 20 N·m
12 - 14 ft-lb

17 - 20 N·m
12 - 14 ft-lb

7

4

5

14

11

12

6

N

10 - 12 N·m
89 - 106 in-lb

18 N·m
13 ft-lb

24 N·m
17 ft-lb

35 N·m
26 ft-lb

24 N·m
18 ft-lb

18 N·m
13 ft-lb

15

16

1

19

9

21

8

10

3

17

22

N

18 N·m
13 ft-lb

18

2

20

N

N

AB

10 - 12 N·m
89 - 106 in-lb

18 N·m
13 ft-lb

18 N·m
13 ft-lb

13

REMOVAL STEPS

1.

IGNITION COILS

2.

BRAKE BOOSTER VACUUM
HOSE CONNECTION

3.

PCV HOSE CONNECTION

4.

CRANKSHAFT POSITION
SENSOR AND CAM POSITION
SENSOR CONNECTOR

5.

ACCELERATOR CABLE
BRACKET

6.

IGNITION POWER TRANSISTOR

7.

WATER OUTLET FITTING
BRACKET

8.

WATER PUMP BRACKET

9.

VACUUM HOSE CONNECTION

10. FUEL PIPE CONNECTION
11. SOLENOID VALVE AND VACUUM

HOSE ASSEMBLY

12. VACUUM CONTROL VALVE

BRACKET

13. MANIFOLD ABSOLUTE

PRESSURE SENSOR

14. EGR VALVE
15. EGR PIPE CONNECTION
16. A/T OIL DIPSTICK ASSEMBLY
17. INTAKE MANIFOLD PLENUM

STAY

REMOVAL STEPS (Continued)

INTAKE MANIFOLD

TSB Revision

INTAKE AND EXHAUST

15-6

18. THROTTLE CABLE

CONNECTION

19. AIR INTAKE FITTING
20. AIR INTAKE FITTING GASKET
21. UPPER INTAKE MANIFOLD

>>D<<

22. INTAKE MANIFOLD PLENUM

GASKET

REMOVAL STEPS (Continued)

AC004650

29

27

28

27

23

26

24

24

26

25

23

26

25

20 - 23 N·m
14 - 17 ft-lb

12 N·m
106 in-lb

8.8 N·m
78 in-lb

4.9 N·m
43 in-lb

ENGINE OIL

O-RING

N

N

N

N

AB

REMOVAL STEPS

>>C<<

23. FUEL HIGH-PRESSURE HOSE

CONNECTION

>>C<<

24. FUEL PRESSURE REGULATOR
25. INJECTOR CONNECTOR

<<A>>

26. FUEL RAIL AND INJECTOR

ASSEMBLY

27. WATER HOSE CONNECTION

>>B<<

28. INTAKE MANIFOLD

>>A<<

29. INTAKE MANIFOLD GASKET

REMOVAL STEPS (Continued)

INTAKE MANIFOLD

TSB Revision

INTAKE AND EXHAUST

15-7

REMOVAL SERVICE POINT

.

<<A>> FUEL RAIL AND INJECTOR ASSEMBLY REMOVAL

CAUTION

Care must be taken when removing the fuel rail: Do not
drop the injectors.
Remove the fuel rail with the injectors attached to it.

INSTALLATION SERVICE POINTS

.

>>A<< INTAKE MANIFOLD GASKET INSTALLATION
Install the gasket with the protrusions in the position illustrated.

.

>>B<< INTAKE MANIFOLD INSTALLATION
Tighten the nuts by the following procedure.

.

ACX02434 AB

PROTRUSION

FRONT

PROTRUSION

ORDER

MOUNTING NUT

TIGHTENING
TORQUE

1st

Right-bank nuts

6.4 N

⋅m

(56 in-lb)

2nd

Left-bank nuts

20

− 23 N⋅m

(14

− 17 ft-lb)

3rd

Right-bank nuts

20

− 23 N⋅m

(14

− 17 ft-lb)

4th

Left-bank nuts

20

− 23 N⋅m

(14

− 17 ft-lb)

5th

Right-bank nuts

20

− 23 N⋅m

(14

− 17 ft-lb)

ACX02435

: LEFT BANK

AB

FRONT

INTAKE MANIFOLD

: RIGHT BANK

INTAKE MANIFOLD

TSB Revision

INTAKE AND EXHAUST

15-8

>>C<< FUEL PRESSURE REGULATOR/FUEL
HIGH-PRESSURE HOSE INSTALLATION

CAUTION

Be careful not to allow any engine oil to enter the fuel rail.
When connecting the fuel pressure regulator and the fuel
high-pressure hose to the fuel rail, apply a small amount of new
engine oil to the O-ring. Then insert the fuel high-pressure
hose, being careful not to damage the O-ring.

.

>>D<< INTAKE MANIFOLD PLENUM GASKET
INSTALLATION
Install the gasket with the protrusion in the position illustrated.

INSPECTION

M1151003100393

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 (0.006 inch) or less
Limit: 0.20 mm (0.008 inch)

AC000165

FUEL RAIL

FUEL RAIL

FUEL
HIGH-PRESSURE
HOSE

AC

FUEL PRESSURE
REGULATOR

ACX02436

FRONT

PROTRUSION

AB