Mitsubishi Montero (2004+). Manual - part 384

INTAKE MANIFOLD

TSB Revision

INTAKE AND EXHAUST

15-7

INTAKE MANIFOLD

REMOVAL AND INSTALLATION

M1151003000846

Pre-removal Operation
• Fuel Discharge Prevention (Refer to GROUP 13A, 

On-vehicle Service 

P.13A-998

.)

• Throttle Body Removal (Refer t o GROUP 13A, Throttle 

Body 

P.13A-1012

.)

Post-installation Operation
Throttle Body installation (Refer to GROUP 13A, Throttle 
Body 

P.13A-1012

.)

AC204050

11 ± 1 N·m
98 ± 8 in-lb

11 ± 1 N·m
98 ± 8 in-lb

11 ± 1 N·m
98 ± 8 in-lb

11 ± 1 N·m
98 ± 8 in-lb

9.0 ± 1.0 N·m
80 ± 9 in-lb

9.0 ± 1.0 N·m
80 ± 9 in-lb

9.0 ± 1.0 N·m
80 ± 9 in-lb

11 ± 1 N·m
98 ± 8 in-lb

9.0 ± 1.0 N·m
80 ± 9 in-lb

9.0 ± 1.0 N·m
80 ± 9 in-lb

14 ± 1 N·m
120 ± 13 in-lb

36 ± 6 N·m
27 ± 4 ft-lb

59 ± 10 N·m
44 ± 7 ft-lb

18 ± 2 N·m
13 ± 2 ft-lb

18 ± 2 N·m
13 ± 2 ft-lb

9.0 ± 1.0 N·m
80 ± 9 in-lb

5.0 ± 1.0 N·m
44 ± 9 in-lb

24 ± 3 N·m
18 ± 2 ft-lb

11 ± 1 N·m
98 ± 8 in-lb

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

N

N

N

N

N

N

AB

18 ± 2 N·m
13 ± 2 ft-lb

REMOVAL STEPS

1.

EGR VALVE CONNECTOR 
CONNECTION

2.

EVAPORATIVE EMISSION 
PURGE SOLENOID VALVE 
CONNECTOR CONNECTION

3.

RIGHT BANK HEATED OXYGEN 
SENSOR (FRONT) CONNECTOR 
CONNECTION

REMOVAL STEPS (Continued)

INTAKE MANIFOLD

TSB Revision

INTAKE AND EXHAUST

15-8

4.

MANIFOLD ABSOLUTE 
PRESSURE SENSOR 
CONNECTOR CONNECTION

5.

CAPACITOR CONNECTOR 
CONNECTION

6.

KNOCK SENSOR CONNECTOR 
CONNECTION

7.

CONTROL WIRING HARNESS 
AND CAMSHAFT POSITION 
SENSOR WIRING HARNESS 
COMBINATION CONNECTOR 
CONNECTION

8.

GROUND CABLE

9.

INJECTOR CONNECTOR 
CONNECTION

10. CONTROL WIRING HARNESS 

AND INJECTOR WIRING 
HARNESS COMBINATION 
CONNECTOR CONNECTION

11. INTAKE MANIFOLD TUNING 

SOLENOID CONNECTOR 
CONNECTION

12. ENGINE COOLANT 

TEMPERATURE SENSOR 
CONNECTOR CONNECTION

13. ENGINE COOLANT 

TEMPERATURE GAUGE UNIT 
CONNECTOR CONNECTION

14. CRANKSHAFT POSITION 

SENSOR CONNECTOR 
CONNECTION

15. GROUND CABLE
16. KNOCK SENSOR AND 

CAMSHAFT POSITION SENSOR 
WIRING HARNESS 
COMBINATION CONNECTOR 
BRACKET

17. CONTROL WIRING HARNESS 

AND INJECTOR WIRING 
HARNESS COMBINATION 
CONNECTOR

18. CONNECTOR BRACKET
19. PCV HOSE CONNECTION
20. FUEL PIPE
21. VACUUM HOSE CONNECTION
22. WATER OUTLET FITTING 

BRACKET

23. EGR PIPE
24. EGR PIPE GASKET
25. INTAKE MANIFOLD PLENUM 

STAY

26. RIGHT BANK HEATED OXYGEN 

SENSOR (FRONT) CONNECTOR

27. FUEL PIPE CLIP
28. INTAKE MANIFOLD PLENUM

>>D<<

29. INTAKE MANIFOLD PLENUM 

GASKET

REMOVAL STEPS (Continued)

30. MANIFOLD ABSOLUTE 

PRESSURE SENSOR

31. O-RING
32. SOLENOID VALVE AND VACUUM 

HOSE ASSEMBLY

33. CAPACITOR
34. EGR VALVE
35. EGR VALVE GASKET
36. PURGE HOSE
37. EVAPORATIVE EMISSION 

PURGE SOLENOID VALVE

38. INTAKE MANIFOLD TUNING 

VALVE ASSEMBLY

39. INTAKE MANIFOLD TUNING 

VALVE GASKET P

40. INTAKE MANIFOLD TUNING 

VALVE GASKET S

REMOVAL STEPS (Continued)

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