Mitsubishi Montero Sport (2004+). Manual — part 588

15-1

GROUP 15

INTAKE AND

EXHAUST

CONTENTS

GENERAL DESCRIPTION. . . . . . . . .

15-2

INTAKE AND EXHAUST DIAGNOSIS

15-2

INTRODUCTION. . . . . . . . . . . . . . . . . . . . .

15-2

TROUBLESHOOTING STRATEGY . . . . . .

15-2

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

15-2

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

15-2

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

15-3

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

15-4

REMOVAL AND INSTALLATION . . . . . . . .

15-4

INTAKE MANIFOLD . . . . . . . . . . . . .

15-5

REMOVAL AND INSTALLATION . . . . . . . .

15-5

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

15-8

EXHAUST MANIFOLD . . . . . . . . . . . .

15-9

REMOVAL AND INSTALLATION . . . . . . . .

15-9

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

15-9

EXHAUST PIPE AND MAIN
MUFFLER . . . . . . . . . . . . . . . . . . . . . .

15-10

REMOVAL AND INSTALLATION . . . . . . . .

15-10

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

15-11

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

15-11

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

15-12

GENERAL DESCRIPTION

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INTAKE AND EXHAUST

15-2

GENERAL DESCRIPTION

M1151000100286

The exhaust pipe is divided into four parts.

INTAKE AND EXHAUST DIAGNOSIS

INTRODUCTION

M1151006900235

Intake leaks usually create driveability issues that
are not obviously related to the intake system.
Exhaust leaks or abnormal noise is caused by
cracks, gaskets and fittings, 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 the system contacts the body and vibra-
tion noise is generated.

TROUBLESHOOTING STRATEGY

M1151007000235

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 system 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 that the malfunction is eliminated.

SYMPTOM CHART

M1151007100232

SYMPTOM PROCEDURES

INSPECTION PROCEDURE 1: Exhaust Leakage

DIAGNOSIS

STEP 1. Start the engine. Have an assistant stay
in the driver’s seat. Raise the vehicle on a hoist.
Have the assistant rev the engine while
searching for exhaust leaks.

Q: Is the exhaust leaking?

YES :

Go to Step 2.

NO :

The procedure is complete.

STEP 2. Check the gasket for cracks, damage.

Q: Is the gasket damaged?

YES :

Replace the gasket, then go Step 1.

NO :

Go to Step 3.

STEP 3. Check for loosening in each coupling
section.

Q: Is there any loosening in each section?

YES :

Tighten, then go to Step 1.

NO :

There is no action to be taken.

SYMPTOM

INSPECTION PROCEDURE

REFERENCE PAGE

Exhaust Leakage

1

P.15-2

Abnormal Noise

2

P.15-3

SPECIAL TOOL

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INTAKE AND EXHAUST

15-3

INSPECTION PROCEDURE 2: Abnormal Noise

DIAGNOSIS

STEP 1. Start the engine. Have an assistant stay
in the driver’s seat. Raise the vehicle on a hoist.
Have the assistant rev the engine while
searching for exhaust leaks.

Q: Is any abnormal noise generated?

YES :

Go to Step 2.

NO :

The procedure is complete.

STEP 2. 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 1.

NO :

Go to Step 3.

STEP 3. Check the hanger for cracks.

Q: Is the hanger cracked?

YES :

Replace, then go to Step 1.

NO :

Go to Step 4.

STEP 4. 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 1.

NO :

Go to Step 5.

STEP 5. Check the heat protectors.

Q: Are any heat protectors loose or damaged?

YES :

Tighten or replace, then go to Step 1.

NO :

Go to Step 6.

STEP 6. Check the pipes, catalytic converters
and muffler for damage.

Q: Are the pipes, catalytic converters and muffler

damaged?

YES :

Replace, then go to Step 1. (For the

removal of the catalytic converter, refer to
GROUP 17

P.17-118

.)

NO :

There is no action to be taken.

SPECIAL TOOL

M1151000600247

TOOL

TOOL NUMBER AND
NAME

SUPERSESSION

APPLICATION

MD998770
Oxygen sensor wrench

MD998770-01 or General
service tool

Removal and installation
of heated oxygen sensor

AIR CLEANER

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INTAKE AND EXHAUST

15-4

AIR CLEANER

REMOVAL AND INSTALLATION

M1151002100549

AC309265

3.9 N·m
35 in-lb

3.9 N·m
35 in-lb

3.9 N·m
35 in-lb

8.8 N·m
78 in-lb

8.8 N·m
78 in-lb

7

2

1

3

4

5

6

2

AB

REMOVAL STEPS

1.

AIR INTAKE HOSE

2.

RESONATOR

3.

AIR FLOW SENSOR ASSEMBLY

4.

AIR CLEANER COVER

5.

AIR CLEANER ELEMENT

6.

AIR CLEANER BODY

7.

AIR CLEANER BRACKET

REMOVAL STEPS (Continued)