Mitsubishi Montero (2002-2004). Manual - part 446

INTAKE MANIFOLD AND FUEL PARTS

TSB Revision

ENGINE OVERHAUL

11B-17

INTAKE MANIFOLD AND FUEL PARTS

REMOVAL AND INSTALLATION

M1113004300165

AK201075

11 ± 1 N·m
97 ± 9 in-lb

14 ± 1 N·m
124 ± 9 in-lb

29 ± 10 N·m
22 ± 7 ft-lb

19 ± 1 N·m
14 ± 1 ft-lb

14 ± 1 N·m
124 ± 9 in-lb

14 ± 1 N·m
124 ± 9 in-lb

12 ± 1 N·m
106 ± 9 in-lb

8.8 ± 1.0 N·m
78 ± 9 in-lb

12 ± 1 N·m
106 ± 9 in-lb

4

6

7

1

2

3

9

10

11

8

12

13

14

15

16

17

7

18

19

20

AB

12 ± 1 N·m
106 ± 9 in-lb

5

REMOVAL STEPS

>>G<<

1. ENGINE COOLANT TEMPERATURE 

GAUGE UNIT

>>F<<

2. ENGINE COOLANT TEMPERATURE 

SENSOR

3. WATER OUTLET FITTING
4. WATER OUTLET FITTING GASKET
5. BLOW-BY HOSE

>>D<<

6. WATER OUTLET PIPE

>>D<<

7. O-RING
8. WATER HOSE
9. WATER INLET FITTING

>>E<<

10. THERMOSTAT
11. THERMOSTAT CASE
12. THERMOSTAT CASE GASKET
13. FITTING
14. FITTING GASKET
15. WATER HOSE
16. WATER PASSAGE
17. WATER PASSAGE GASKET
18. WATER HOSE

>>D<<

19. WATER PIPE

>>D<<

20. O-RING

REMOVAL STEPS (Continued)

INTAKE MANIFOLD AND FUEL PARTS

TSB Revision

ENGINE OVERHAUL

11B-18

AK201076

12 ± 1 N·m
106 ± 9 in-lb

22 ± 1 N·m
16 ± 1 ft-lb

9 ± 1 N·m
80 ± 9 in-lb

9 ± 1 N·m
80 ± 9 in-lb

21

22

23

24

25

26

27

28

29

30

31

32

33

34

AB

REMOVAL STEPS

21. INJECTOR HARNESS
22. INJECTOR AND FUEL RAIL
23. INSULATOR

>>C<<

24. FUEL PRESSURE REGULATOR
25. O-RING
26. INSULATOR

>>B<<

27. INJECTOR

28. O-RING
29. GROMMET
30. FUEL PIPE
31. O-RING
32. FUEL RAIL

>>A<<

33. INTAKE MANIFOLD
34. INTAKE MANIFOLD GASKET

REMOVAL STEPS (Continued)

INTAKE MANIFOLD AND FUEL PARTS

TSB Revision

ENGINE OVERHAUL

11B-19

INSTALLATION SERVICE POINTS

.

>>A<< INTAKE MANIFOLD INSTALLATION
1. Tighten the nuts on the right bank to 6.4 N

⋅m (56 in-lb).

2. Tighten the nuts on the left bank to the specified torque.

Tightening torque: 22 

± 1 N⋅m (16 ± 1 ft-lb)

3. Tighten the nuts on the right bank to the specified torque.

Tightening torque: 22 

± 1 N⋅m (16 ± 1 ft-lb)

4. Tighten the nuts on the left bank and those on the right bank 

again in that order.

Tightening torque: 22 

± 1 N⋅m (16 ± 1 ft-lb)

.

>>B<< INJECTOR INSTALLATION

CAUTION

Use care not to let engine oil enter the fuel rail.
1. Before installing the pressure regulator, lubricate the O-ring 

with a drop of new engine oil for easy installation.

2. Insert the injector top end into the fuel rail. Be careful not to 

damage the O-ring during installation.

.

>>C<< FUEL PRESSURE REGULATOR INSTALLATION 

CAUTION

Do not let engine oil enter the fuel rail.
Before installing the pressure regulator, lubricate the O-ring 
with a drop of new engine oil for easy installation.

.

>>D<< O-RING AND WATER PIPE INSTALLATION 

CAUTION

Keep the O-ring free of oil or grease.
Wet the O-ring (with water) to ease assembly.

.

AKX00680

TIMING
BELT SIDE

NUT "R"

NUT "L"

AB

AKX00748

FUEL RAIL

INJECTOR

AB

AKX00711

O-RING

WATER INLET 
PIPE

AB

INTAKE MANIFOLD AND FUEL PARTS

TSB Revision

ENGINE OVERHAUL

11B-20

>>E<< THERMOSTAT INSTALLATION
Install the thermostat in the thermostat case with its jiggle valve 
located at the top position.

.

>>F<< SEALANT APPLICATION TO ENGINE COOLANT 
TEMPERATURE SENSOR 
Apply 3M

ä AAD Part number 8731 or equivalent to the engine 

coolant temperature sensor.

.

>>G<< SEALANT APPLICATION TO ENGINE COOLANT 
TEMPERATURE GAUGE UNIT 
Apply 3M

ä AAD Part number 8672 or equivalent to the engine 

coolant temperature gauge unit.

AKX01453

JIGGLE
VALVE

AB

AKX00686

AKX00687