Mitsubishi Montero (2002-2004). Manual — part 1080

INTAKE MANIFOLD

TSB Revision

INTAKE AND EXHAUST

15-9

REMOVAL SERVICE POINT

.

<<A>> FUEL RAIL (WITH INJECTORS) 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.

AC204059AB

N

41

43

45

46

46

46

48

49

48

50

N

N

N

22 ± 1 N·m
16 ± 1 ft-lb

5.0 ± 1.0 N·m
44 ± 9 in-lb

12 ± 1 N·m
102 ± 13 in-lb

O-RING

41

43

ENGINE OIL

9.0 ± 2.0 N·m
80 ± 17 in-lb

47

42

44

REMOVAL STEPS

>>C<<

41. FUEL HIGH-PRESSURE HOSE

CONNECTION

>>C<<

42. O-RING

>>C<<

43. FUEL PRESSURE REGULATOR

>>C<<

44. O-RING
45. INJECTOR CONNECTOR

<<A>>

46. FUEL RAIL (WITH INJECTORS)
47. INSULATORS
48. WATER HOSE CONNECTION

>>B<<

49. INTAKE MANIFOLD

>>A<<

50. INTAKE MANIFOLD GASKET

REMOVAL STEPS (Continued)

INTAKE MANIFOLD

TSB Revision

INTAKE AND EXHAUST

15-10

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.

.

>>C<< O-RING/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 hose high-pressure
hose, being careful not to damage the O-ring.

.

ACX02434 AB

PROTRUSION

FRONT

PROTRUSION

ORDER

MOUNTING NUTS

TIGHTENING TORQUE

1st

Right-bank nuts

6.5

± 1.5 N⋅m (58 ± 13 in-lb)

2nd

Left-bank nuts

22

± 1 N⋅m (16 ± 1 ft-lb)

3rd

Right-bank nuts

22

± 1 N⋅m (16 ± 1 ft-lb)

4th

Left-bank nuts

22

± 1 N⋅m (16 ± 1 ft-lb)

5th

Right-bank nuts

22

± 1 N⋅m (16 ± 1 ft-lb)

ACX02435

: LEFT BANK

AB

FRONT

INTAKE MANIFOLD

: RIGHT BANK

AC000165

FUEL RAIL

FUEL RAIL

HIGH-PRESSURE
FUEL HOSE

AB

FUEL PRESSURE
REGULATOR

INTAKE MANIFOLD

TSB Revision

INTAKE AND EXHAUST

15-11

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

INSPECTION

M1151003100467

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)

AC204098

FRONT

PROTRUSION

AB

EXHAUST MANIFOLD

TSB Revision

INTAKE AND EXHAUST

15-12

EXHAUST MANIFOLD

REMOVAL AND INSTALLATION

M1151003300416

INSPECTION

M1151003400402

Check the following points; replace the part if a problem is
found.

.

Exhaust Manifold Check
1. Check for damage or cracking of any part.
2. Using a straight edge and a feeler gauge, check for

distortion of the cylinder head installation surface.

Pre-removal and Post-installation Operation
• Front Exhaust Pipe Removal and Installation (Refer to

P.15-13

.)

• Air Cleaner Removal and Installation (Refer to

P.15-6

.)

• Battery and Battery Tray Removal and Installation

AC204049

1

2

3

4

5

6

7

14 ± 1 N·m
120 ± 13 in-lb

14 ± 1 N·m
120 ± 13 in-lb

44 ± 5 N·m
33 ± 3 ft-lb

18 ± 2 N·m
13 ± 2 ft-lb

N

N

N

59 ± 10 N·m
44 ± 7 ft-lb

44 ± 5 N·m
33 ± 3 ft-lb

8

9

10

14 ± 1 N·m
120 ± 13 in-lb

24 ± 4 N·m
18 ± 3 ft-lb

44 ± 8 N·m
33 ± 5 ft-lb

AB

REMOVAL STEPS

1. EGR PIPE
2. EGR PIPE GASKET
3. HEAT PROTECTOR <RH>
4. EXHAUST MANIFOLD <RH>
5. EXHAUST MANIFOLD GASKET

<RH>

6. ENGINE OIL DIPSTICK GUIDE

7. TRANSMISSION FLUID DIPSTICK

GUIDE

8. HEAT PROTECTOR <LH>
9. EXHAUST MANIFOLD <LH>
10. EXHAUST MANIFOLD GASKET

<LH>

REMOVAL STEPS (Continued)