15-1

GROUP 15

INTAKE AND
EXHAUST
CONTENTS

GENERAL INFORMATION . . . . . . . . 15-2 REMOVAL AND INSTALLATION <4G63> . 15-5

REMOVAL AND INSTALLATION <4G69> . 15-7
SERVICE SPECIFICATION . . . . . . . . 15-2 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 15-9

SEALANT. . . . . . . . . . . . . . . . . . . . . . 15-2 EXHAUST MANIFOLD . . . . . . . . . . . . 15-10

REMOVAL AND INSTALLATION <4G63> . 15-10
SPECIAL TOOL . . . . . . . . . . . . . . . . . 15-2 REMOVAL AND INSTALLATION <4G69> . 15-11
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 15-12
AIR CLEANER . . . . . . . . . . . . . . . . . . 15-3
REMOVAL AND INSTALLATION <4G63> . 15-3 EXHAUST PIPE AND MAIN
REMOVAL AND INSTALLATION <4G69> . 15-4 MUFFLER . . . . . . . . . . . . . . . . . . . . . . 15-13
REMOVAL AND INSTALLATION . . . . . . . . 15-13
INTAKE MANIFOLD . . . . . . . . . . . . . 15-5
15-2 INTAKE AND EXHAUST
GENERAL INFORMATION

GENERAL INFORMATION
M1151000100468
The exhaust pipe is divided into three parts.

SERVICE SPECIFICATION
M1151000300484

Item Standard value Limit

Manifold distortion of the installation surface mm 0.15 or less 0.20

SEALANT
M1151000500217

Item Specified sealant

Thermostat case MITSUBISHI GENUINE Part No.MD970389 or equivalent
Thermostat case assembly bolt 3M Stud Locking 4170 or equivalent

SPECIAL TOOL
M1151000600441

Tool Number Name Use

MD998770 Oxygen sensor wrench Removal and installation of
oxygen sensor
 INTAKE AND EXHAUST
AIR CLEANER
15-3
AIR CLEANER
REMOVAL AND INSTALLATION <4G63>
M1151002100550

CAUTION
Parts marked by * are made of recycled-paper mixed plastic material, so observe the following
precautions.
• Avoid any shock or load to these parts when removing and installing them.
• When installing, securely set the air cleaner cover and the resonator clamp to the air cleaner body.
NOTE: Parts marked by * are made of recycled-paper mixed plastic material. Dispose of according to state
and local laws

3.9 ± 1.0 N·m

6
11
12
1* 5

Clamp 3.9 ± 1.0 N·m

8.8 ± 1.0 N·m

N 9
3*

8.8 ± 1.0 N·m

8
4* 10*
2* 7
11 ± 1 N·m
8.8 ± 1.0 N·m

13 22 ± 4 N·m
AC203703 AB

Removal steps Removal steps (Continued)

1. Resonator 8. Air flow sensor assembly
2. Air cleaner element 9. Gasket
3. Air duct 10. Air cleaner cover
4. Air cleaner body 11. Resonator
5. Air flow sensor connector 12. Air intake hose
6. Breather hose connection 13. Air cleaner bracket
7. Air cleaner cover and air flow sensor
assembly
15-4 INTAKE AND EXHAUST
AIR CLEANER

REMOVAL AND INSTALLATION <4G69>

M1151002100561

CAUTION
Parts marked by * are made of recycled-paper mixed plastic material, so observe the following
precautions.
• Avoid any shock or load to these parts when removing and installing them.
• When installing, securely set the air cleaner cover and the resonator clamp to the air cleaner body.
NOTE: Parts marked by * are made of recycled-paper mixed plastic material. Dispose of according to state
and local laws

9 3.0 ± 0.5 N·m

3.0 ± 0.5 N·m

4.0 ± 1.0 N·m

1.6 ± 0.6 N·m
1* 3.9 ± 1.0 N·m
5
6

Clamp 3.9 ± 1.0 N·m

8.8 ± 1.0 N·m 7
3

10

8*
2*
11 ± 1 N·m 4*
8.8 ± 1.0 N·m

11 22 ± 4 N·m
AC304211AC

Removal steps Removal steps (Continued)

1. Resonator 7. Air flow sensor assembly
2. Air cleaner element 8. Air cleaner cover
3. Air duct 9. Resonator
4. Air cleaner body 10. Air intake hose
5. Air flow sensor connector 11. Air cleaner bracket
6. Breather hose connection
 INTAKE AND EXHAUST
INTAKE MANIFOLD
15-5
INTAKE MANIFOLD
REMOVAL AND INSTALLATION <4G63>
M1151003000879

Pre-removal Operation Post-installation Operation

• Fuel Line Pressure Reduction [Refer to GROUP 13A, • Fuel Delivery Pipe and Fuel Injector assembly Installation
On-vehicle Service − Fuel Pump Connector (Refer to GROUP 13A, Injector P.13A-338).
Disconnection (How to Reduce Pressurized Fuel Lines) • Throttle Body Installation (Refer to GROUP 13A, Throttle
P.13A-328.] Body P.13A-340).
• Throttle Body Removal (Refer to GROUP 13A, Throttle • Accelerator Cable Adjustment (Refer to GROUP 17,
Body P.13A-340). On-vehicle Service − Accelerator Cable Check and
• Fuel Delivery Pipe and Fuel Injector assembly Removal Adjustment P.17-5).
(Refer to GROUP 13A, Injector P.13A-338). • Fuel Leak Check

2
1 5.0 ± 1.0 N·m
3
5.0 ± 1.0 N·m
4
5
11 ± 1 N·m

10 6

13 ± 1 N·m

7
N9

(Engine oil) AC301313 AB

Removal steps Removal steps (Continued)

1. Purge control solenoid valve 5. Earth cable connection
connector 6. Emission control equipment hose
2. EGR control solenoid valve 7. PCV hose
connector 8. Oil level gauge and guide
3. Detonation sensor connector 9. O-ring
4. Accelerator cable connection 10. Detonation sensor connector clamp
15-6 INTAKE AND EXHAUST
INTAKE MANIFOLD

11 ± 1 N·m

11

9.0 ± 1.0 N·m

14
20 ± 2 N·m 36 ± 6 N·m

20 ± 2 N·m
16
36 ± 6 N·m

12

36 ± 6 N·m 13 N
17 N

20 ± 2 N·m

15

31 ± 3 N·m
AC301314 AB

Removal steps Removal steps (Continued)

11. Vacuum hose and pipe assembly 15. Intake manifold stay
12. EGR valve 16. Intake manifold assembly
13. EGR valve gasket 17. Intake manifold gasket
14. Brake booster vacuum hose
connection
 INTAKE AND EXHAUST
INTAKE MANIFOLD
15-7
REMOVAL AND INSTALLATION <4G69>
M1151003000880

Pre-removal Operation Post-installation Operation

• Fuel Line Pressure Reduction [Refer to GROUP 13B, • Delivery Pipe and Injector Assembly Installation (Refer to
On-vehicle Service − Fuel Pump Connector GROUP 13B, Injector P.13B-437).
Disconnection (How to Reduce Pressurized Fuel Lines) • Throttle Body Installation (Refer to GROUP 13B, Throttle
P.13B-428]. Body P.13B-438).
• Engine Coolant Draining (Refer to GROUP 14, On-vehicle • Air Cleaner Cover and Air Intake Hose Installation (Refer
Service − Engine Coolant Replacement P.14-17). to P.15-4).
• Air Cleaner Cover and Air Intake Hose Removal (Refer to • Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
P.15-4). Service − Engine Coolant Replacement P.14-17).
• 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).

<R.H. drive vehicle> <L.H. drive vehicle>

4
4 6 3
5
20 17
6 21
3
11 ± 1 N·m 5 19
7 24 ± 3 N·m

8 1
5.0 ± 1.0 N·m 24 ± 4 N·m
27
18
2N
24 22 N
29 12 9
11
28 N

10
13
11 ± 1 N·m

23 24 ± 3 N·m

14 20 ± 2 N·m

26
25
13 ± 1 N·m
15

N 16
31 ± 3 N·m
(Engine oil)
AC309416AB

Removal steps Removal steps (Continued)

1. EGR valve 6. Brake booster vacuum pipe
>>C<< 2. EGR valve gasket 7. Brake booster vacuum hose
3. Capacitor connector 8. Evaporative emission vacuum hose
4. Brake booster vacuum hose connection
5. Capacitor
15-8 INTAKE AND EXHAUST
INTAKE MANIFOLD

Removal steps (Continued) INSTALLATION SERVICE POINTS

9. Manifold absolute pressure sensor
>>A<< THERMOSTAT CASE ASSEMBLY
connector
10. Detonation sensor connector
INSTALLATION
11. Evaporative emission purge solenoid 1. Use a gasket scraper or wire brush to completely
valve connector eliminate all gasket material on the gasket
12. Harness clamp mounting surface.
13. Detonation sensor connector clamp
14. Harness clamp Thermostat case assembly
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
Ø3 mm
>>A<< 21. Thermostat housing assembly
22. O-ring AC305212 AD
23. Detonation sensor harness clamp
24. Manifold absolute pressure sensor 2. Apply a bead of the sealant to the cylinder head
25. Harness clamp mating surface of the thermostat case assembly
26. Intake manifold stay as shown.
27. Intake manifold
Specified Sealant: MITSUBISHI GENUINE
28. Intake manifold gasket
29. Evaporative emission purge solenoid PART No.MD970389 or equivalent
valve, evaporative emission vacuum Thermostat case assembly
hose and pipe assembly

REMOVAL SERVICE POINT

<<A>> RADIATOR LOWER HOSE
DISCONNECTION

AC303724AE

3. Apply sealant to the thread of the thermostat case

assembly bolts as shown.
Mating marks Specified Sealant: 3M Stud Locking 4170 or
equivalent
AC200641AC 4. With the sealant still wet (within 15 minutes after
Make mating marks on the radiator hose and the the sealant is applied), install the thermostat case
hose clamp. Disconnect the radiator hose. assembly. Do not apply the sealant in an area
more than the required.
 INTAKE AND EXHAUST
INTAKE MANIFOLD
15-9
>>B<< RADIATOR LOWER HOSE CONNECTION >>C<< EGR VALVE GASKET INSTALLATION

Projection

Notched
part

Water inlet fitting Mating marks Gasket

Notched
AC200642 AE part AC302358AE

1. Insert each hose as far as the projection of the Install the EGR valve gasket as shown in the
water inlet fitting. illustration.
2. Align the mating marks on the radiator hose and
INSPECTION
hose clamp, and then connect the radiator hose. 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
15-10 INTAKE AND EXHAUST
EXHAUST MANIFOLD

EXHAUST MANIFOLD
REMOVAL AND INSTALLATION <4G63>
M1151003300717

8N
7 29 ± 3 N·m

14 ± 1 N·m 1

6 44 ± 5 N·m

29 ± 3 N·m
49 ± 5 N·m 14 ± 1 N·m
35 ± 6 N·m

5 2
44 ± 5 N·m
4N
49 ± 10 N·m
3 AC301312 AB

Removal steps Use special tool oxygen sensor wrench (MD998770)

<<A>> >>A<< 1. Oxygen sensor to remove the oxygen sensor.
2. Exhaust manifold cover
3. Front exhaust pipe connection INSTALLATION SERVICE POINT
4. Exhaust pipe gasket
>>A<< OXYGEN SENSOR INSTALLATION
5. Exhaust manifold bracket
6. Engine hanger
7. Exhaust manifold
8. Exhaust manifold gasket
MD998770
REMOVAL SERVICE POINT
<<A>> OXYGEN SENSOR REMOVAL

Oxygen sensor
MD998770
AC212566AB

Use special tool oxygen sensor wrench (MD998770)

to install the oxygen sensor.

Oxygen sensor

AC212566AB
 INTAKE AND EXHAUST
EXHAUST MANIFOLD
15-11
REMOVAL AND INSTALLATION <4G69>
M1151003300728

14 ± 1 N·m

1
1

44 ± 5 N·m

14 ± 1 N·m
44 ± 5 N·m

N 5 4
49 ± 5 N·m
3

35 ± 6 N·m
44 ± 5 N·m AC309280AC

Removal steps Use special tool oxygen sensor wrench (MD998770)

<<A>> >>A<< 1. Oxygen sensor to remove the oxygen sensor.
2. Exhaust manifold cover
• Front exhaust pipe (Refer to P.15-13.) INSTALLATION SERVICE POINT
3. Exhaust manifold bracket B >>A<< OXYGEN SENSOR INSTALLATION
4. Exhaust manifold
5. Exhaust manifold gasket
6. Exhaust manifold bracket A
MD998770
REMOVAL SERVICE POINT
<<A>> OXYGEN SENSOR REMOVAL

Oxygen sensor
MD998770
AC212566AB

Use special tool oxygen sensor wrench (MD998770)

to install the oxygen sensor.
Oxygen sensor

AC212566AB
15-12 INTAKE AND EXHAUST
EXHAUST MANIFOLD

INSPECTION 2. Using a straight edge and a feeler gauge, check

M1151003400480 for distortion of the cylinder head installation
Check the following points; replace the part if a surface.
problem is found.
Standard value: 0.15 mm or less
Exhaust Manifold Check Limit: 0.20 mm
1. Check for damage or cracking of any part.
 INTAKE AND EXHAUST
EXHAUST PIPE AND MAIN MUFFLER
15-13
EXHAUST PIPE AND MAIN MUFFLER
REMOVAL AND INSTALLATION
M1151008700367

<4G63>
13 ± 2 N·m
6
13 ± 2 N·m

7
1

13 ± 2 N·m 9 6
13 ± 2 N·m

11 N 12
4 N 5
2 45 ± 5 N·m

8N 59 ± 10 N·m
10 N

49 ± 10 N·m
49 ± 10 N·m
AC301054 AC

<4G69>
13 ± 2 N·m
6
13 ± 2 N·m

7
13 ± 2 N·m 1
13 ± 2 N·m 9 6
12 N 10 5N
N 11 4

2 45 ± 5 N·m
N 8 59 ± 10 N·m

3 3 49 ± 10 N·m
49 ± 10 N·m
AC309215 AB
44 ± 5 N·m 44 ± 5 N·m
Exhaust main muffler removal Centre exhaust pipe removal
steps steps (Continued)
1. Exhaust main muffler 8. Exhaust pipe gasket
5. Exhaust pipe gasket 9. Hanger
6. Hanger Front exhaust pipe removal
7. Exhaust pipe damper steps
Centre exhaust pipe removal • Centre under cover (front) (Refer to
steps GROUP 51, Under Cover P.51-19).
2. Centre exhaust pipe <<A>> >>A<< 3. Oxygen sensor <4G69>
5. Exhaust pipe gasket 4. Front exhaust pipe
10. Exhaust pipe gasket
15-14 INTAKE AND EXHAUST
EXHAUST PIPE AND MAIN MUFFLER

Front exhaust pipe removal Use special tool oxygen sensor wrench (MD998770)
steps (Continued) to remove the oxygen sensor.
11. Exhaust pipe gasket
12. Hanger INSTALLATION SERVICE POINT
REMOVAL SERVICE POINT >>A<< OXYGEN SENSOR INSTALLATION

<<A>> OXYGEN SENSOR REMOVAL

MD998770

MD998770

Oxygen sensor

Oxygen sensor AC212566AB

AC212566AB
Use special tool oxygen sensor wrench (MD998770)
to install the oxygen sensor.