Mitsubishi Montero Sport (2004+). Manual - part 589

INTAKE MANIFOLD

TSB Revision

INTAKE AND EXHAUST

15-5

INTAKE MANIFOLD

REMOVAL AND INSTALLATION

M1151003000857

Pre-removal and Post-installation Operation
• Throttle Body Removal and Installation (Refer to GROUP 

13A, Throttle Body 

P.13A-902

).

AC004649

4.9 N·m
43 in-lb

8.8 N·m
78 in-lb

8.8 N·m
78 in-lb

22 N·m
16 ft-lb

18 N·m
13 ft-lb

10 - 12 N·m
89 - 106 in-lb

10 - 12 N·m
89 - 106 in-lb

17 - 20 N·m
12 - 14 ft-lb

17 - 20 N·m
12 - 14 ft-lb

7

4

5

14

11

12

6

N

10 - 12 N·m
89 - 106 in-lb

18 N·m
13 ft-lb

24 N·m
17 ft-lb

35 N·m
26 ft-lb

24 N·m
18 ft-lb

18 N·m
13 ft-lb

15

16

1

19

9

21

8

10

3

17

22

N

18 N·m
13 ft-lb

18

2

20

N

N

AB

10 - 12 N·m
89 - 106 in-lb

18 N·m
13 ft-lb

18 N·m
13 ft-lb

13

REMOVAL STEPS

1.

IGNITION COILS

2.

BRAKE BOOSTER VACUUM 
HOSE CONNECTION

3.

PCV HOSE CONNECTION

4.

CRANKSHAFT POSITION 
SENSOR AND CAM POSITION 
SENSOR CONNECTOR

5.

ACCELERATOR CABLE 
BRACKET

6.

IGNITION POWER TRANSISTOR

7.

WATER OUTLET FITTING 
BRACKET

8.

WATER PUMP BRACKET

9.

VACUUM HOSE CONNECTION

10. FUEL PIPE CONNECTION
11. SOLENOID VALVE AND VACUUM 

HOSE ASSEMBLY

12. VACUUM CONTROL VALVE 

BRACKET

13. MANIFOLD ABSOLUTE 

PRESSURE SENSOR

14. EGR VALVE
15. EGR PIPE CONNECTION
16. A/T OIL DIPSTICK ASSEMBLY
17. INTAKE MANIFOLD PLENUM 

STAY

REMOVAL STEPS (Continued)

INTAKE MANIFOLD

TSB Revision

INTAKE AND EXHAUST

15-6

18. THROTTLE CABLE 

CONNECTION

19. AIR INTAKE FITTING
20. AIR INTAKE FITTING GASKET
21. UPPER INTAKE MANIFOLD

>>D<<

22. INTAKE MANIFOLD PLENUM 

GASKET

REMOVAL STEPS (Continued)

AC004650

29

27

28

27

23

26

24

24

26

25

23

26

25

20 - 23 N·m
14 - 17 ft-lb

12 N·m
106 in-lb

8.8 N·m
78 in-lb

4.9 N·m
43 in-lb

ENGINE OIL

O-RING

N

N

N

N

AB

REMOVAL STEPS

>>C<<

23. FUEL HIGH-PRESSURE HOSE 

CONNECTION

>>C<<

24. FUEL PRESSURE REGULATOR
25. INJECTOR CONNECTOR

<<A>>

26. FUEL RAIL AND INJECTOR 

ASSEMBLY

27. WATER HOSE CONNECTION

>>B<<

28. INTAKE MANIFOLD

>>A<<

29. INTAKE MANIFOLD GASKET

REMOVAL STEPS (Continued)

INTAKE MANIFOLD

TSB Revision

INTAKE AND EXHAUST

15-7

REMOVAL SERVICE POINT

.

<<A>> FUEL RAIL AND INJECTOR ASSEMBLY 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.

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.

.

ACX02434 AB

PROTRUSION

FRONT

PROTRUSION

ORDER

MOUNTING NUT

TIGHTENING 
TORQUE 

1st

Right-bank nuts

6.4 N

⋅m

(56 in-lb)

2nd

Left-bank nuts

20 

− 23 N⋅m 

(14 

− 17 ft-lb)

3rd

Right-bank nuts

20 

− 23 N⋅m 

(14 

− 17 ft-lb)

4th

Left-bank nuts

20 

− 23 N⋅m 

(14 

− 17 ft-lb)

5th

Right-bank nuts

20 

− 23 N⋅m 

(14 

− 17 ft-lb)

ACX02435

: LEFT BANK

AB

FRONT

INTAKE MANIFOLD

: RIGHT BANK

INTAKE MANIFOLD

TSB Revision

INTAKE AND EXHAUST

15-8

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

.

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

INSPECTION

M1151003100393

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)

AC000165

FUEL RAIL

FUEL RAIL

FUEL
HIGH-PRESSURE
HOSE

AC

FUEL PRESSURE
REGULATOR

ACX02436

FRONT

PROTRUSION

AB