Mitsubishi Outlander GS45X. Manual — part 1235

THROTTLE BODY AND EGR SYSTEM

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-15

INSTALLATION SERVICE POINTS

.

>>A<< MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR INSTALLATION

CAUTION

• Install the manifold absolute pressure (MAP) sensor,

taking care not to give a shock to it.

• Do not use a manifold absolute pressure (MAP) sensor

that has fallen down.

.

>>B<< EGR INLET PIPE / EXHAUST GAS
RECIRCULATION VALVE SUPPORT / EGR
SUPPORT / EGR SUPPORT STAY A / EGR
SUPPORT STAY B / EGR PIPE INSTALLATION

1. Temporarily tighten each part so that the protrusion of each

gasket is positioned as illustrated.

AK503321

AC

EGR valve

Protrusion

EGR inlet pipe

AK503320

AC

EGR valve pipe

Protrusion

Protrusion

THROTTLE BODY AND EGR SYSTEM

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-16

2. Tighten mounting bolts to the specified tightening torque in

the order shown in the illustration.

Tightening torque: 20

± 2 N⋅m (15 ± 1 ft-lb)

.

>>C<< EXHAUST GAS RECIRCULATION VALVE
GASKET INSTALLATION

Install the Exhaust gas recirculation valve gasket with the diag-
onally shaded area used as the illustrated position so as not to
confuse the front with the back.

.

>>D<< THROTTLE BODY GASKET / THROTTLE
BODY INSTALLATION

1. Make sure that the throttle body gasket is placed before

installing the throttle body.

2. Temporarily tighten throttle body and throttle body stay

mounting bolts at A and B in the illustration.

3. Tighten the throttle body mounting bolt at illustrated position

A to the specified torque.

Tightening torque: 20

± 2 N⋅m (15 ± 1 ft-lb)

4. Tighten the throttle body mounting bolts at illustrated

position B to the specified tightening torque.

Tightening torque: 9.5

± 2.5 N⋅m (84 ± 22 in-lb)

AK503289AC

8

1

2

10

9

7

5

3

4

6

AK503319

AD

EGR valve

Shaded position

AK503290AC

A

B

B

B

B

INTAKE MANIFOLD AND FUEL SYSTEM

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-17

INTAKE MANIFOLD AND FUEL SYSTEM

REMOVAL AND INSTALLATION

M1113032500906

Required Special Tool:

• MB992106: O-ring installer

AK703102AC

1

2

18

19

20

44 ± 8 N·m
33 ± 5 ft-lb

21

20 ± 2 N·m
15 ± 1 ft-lb

22

10 ± 2 N·m
89 ± 17 in-lb

12

15

16

17

13

14

3

4

6

8

9

10

11

5

7

10 ± 2 N·m
89 ± 17 in-lb

20 ± 2 N·m
15 ± 1 ft-lb

20 ± 2 N·m
15 ± 1 ft-lb

20 ± 2 N·m
15 ± 1 ft-lb

20 ± 2 N·m
15 ± 1 ft-lb

3.5 ± 1.5 N·m
31 ± 13 in-lb →

20 ± 2 N·m
15 ± 1 ft-lb

3.5 ± 1.5 N·m
31 ± 13 in-lb →

20 ± 2 N·m
15 ± 1 ft-lb

3.5 ± 1.5 N·m
31 ± 13 in-lb →

20 ± 2 N·m
15 ± 1 ft-lb

3.5 ± 1.5 N·m
31 ± 13 in-lb →

20 ± 2 N·m
15 ± 1 ft-lb

3.5 ± 1.5 N·m
31 ± 13 in-lb →

20 ± 2 N·m
15 ± 1 ft-lb

3.5 ± 1.5 N·m
31 ± 13 in-lb

→

Removal steps

1. Oil dipstick rod
2. O-ring

>>G<<

3. Injector protector rear

>>G<<

4. Bracket

>>G<<

5. Bracket

>>G<<

6. Fuel rail assembly

>>F<<

7. Injection support
8. O-ring

>>F<<

9. Injector

>>E<<

10.O-ring
11. Fuel rail

>>D<<

12.Intake manifold stay
13.Intake manifold stay B
14.Intake manifold stay C
15.Injector protector front

>>C<<

16.Intake manifold
17.Intake manifold gasket
18.Oil dipstick guide
19.O-ring

>>B<<

20.Generator bracket
21.Detonation sensor

>>A<<

22.Engine oil pressure switch

Removal steps (Continued)

INTAKE MANIFOLD AND FUEL SYSTEM

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-18

INSTALLATION SERVICE POINTS

.

>>A<< ENGINE OIL PRESSURE SWITCH INSTAL-
LATION

CAUTION

• Do not allow sealant to squeeze out to the screw tip.
• Do not tighten, exceeding the specified tightening

torque.

1. Completely remove sealant adhering to the oil pressure

switch and cylinder block threaded holes.

2. Apply sealant of 5 mm to the threaded portion of the oil

pressure switch shown in the illustration.

Specified sealant:

Three bond 1212D, Three bond 1215 or equivalent

3. Tighten the oil pressure switch to the cylinder block to the

specified tightening torque.

Tightening torque: 10

± 2 N⋅m (89 ± 17 in-lb)

.

>>B<< GENERATOR BRACKET INSTALLATION

Tighten the Generator bracket to the specified tightening
torque.

Tightening torque: 44

± 8 N⋅m (33 ± 5 ft-lb)

NOTE: Be careful to install mounting bolts because they are
different in length.

.

>>C<< INTAKE MANIFOLD INSTALLATION

CAUTION

Temporarily tighten the inlet manifold because there is a
bolt tightening procedure for the inlet manifold, delivery
pipe and injector protector.
Tighten each inlet manifold bolt and nut to the temporarily
torque of 3.5

± 1.5 N⋅m (31 ± 13 in-lb).

.

>>D<< INLET MANIFOLD STAY INSTALLATION

Make sure that the inlet manifold stay is in intimate contact with
the inlet manifold and cylinder block boss before tightening it to
the specified tightening torque.

Tightening torque: 20

± 2 N⋅m (15 ± 1 ft-lb)

AK600888

1 mm (0.004 inch)

5 mm (0.020 inch)

AE

AK503595AC

B

A

A

B

B

A

A

A :
M10 × 40 mm (1.6 in)

B :
M10 × 35 mm (1.4 in)

AK502727AC