Mitsubishi Car 1999-05

Exhaust Manifold

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Removal & Installation





Click image to see an enlarged view

Fig. Exhaust manifold exploded view-3.5L engine

  1. Remove or disconnect the following:

    Battery negative cable
     
    Exhaust pipe from the exhaust manifold
     
    Condenser electric cooling fan assembly
     

  2.  
  3. If removing the front manifold, remove the oil dipstick and tube from the engine.
  4.  
  5. If removing the rear manifold, disconnect the Exhaust Gas Recirculation (EGR) tube.
  6.  
  7. If removing the rear manifold, remove the intake plenum stay and the roll stopper bracket.
  8.  
  9. Remove or disconnect the following:

    Electrical connector and remove the Heated Oxygen (HO 2 S) sensor
     
    Exhaust manifold mounting bolts the manifold
     

  10.  

To install:

  1. Clean all gasket material from the mating surfaces.
  2.  
  3. Install or connect the following:

    New gasket and install the manifold. Tighten the nuts in a crisscross pattern to 21 ft. lbs. (30 Nm) for the J- engine or to 14 ft. lbs. (19 Nm) for the H- engine.
     
    Heat shields
     
    EGR tube and intake plenum stay and roll stopper bracket, if removed
     
    HO 2 S sensor
     
    Electric cooling fan assembly, air conditioning compressor, dipstick tube and alternator, as required
     
    New flange gasket and connect the exhaust pipe or converter assembly
     
    Negative battery cable and check for exhaust leaks
     

  4.  



Click image to see an enlarged view

Fig. Exploded view of the exhaust manifold -1.5L engine



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Fig. Exhaust manifold exploded view-1.8L engine

  1. Disconnect battery negative cable.
  2.  
  3. Raise the vehicle and support safely.
  4.  
  5. Remove the exhaust pipe to exhaust manifold nuts and separate exhaust pipe. Discard gasket.
  6.  
  7. Lower vehicle.
  8.  
  9. Remove electric cooling fan assembly, if necessary.
  10.  
  11. If the oxygen sensor is located in the manifold, remove the sensor.
  12.  
  13. Disconnect necessary EGR components.
  14.  
  15. Remove outer exhaust manifold heat shield and engine hanger. Detach the electrical connector and remove the oxygen sensor.
  16.  
  17. Remove the exhaust manifold mounting bolts, the inner heat shield and the exhaust manifold.
  18.  

To install:

  1. Clean all gasket material from the mating surfaces and check the manifold for damage.
  2.  
  3. Using a new gasket, install the manifold. For 1.5L engines, tighten the nuts in a crisscross pattern to 13 ft. lbs. (18 Nm). For 1.8L engines, tighten the inner nuts in a crisscross pattern to 13 ft. lbs. (18 Nm) and tighten the two outer (larger) nuts to 22 ft. lbs. (30 Nm).
  4.  
  5. Install the heat shields.
  6.  
  7. Connect EGR components.
  8.  
  9. If removed, install the oxygen sensor.
  10.  
  11. Install the electric cooling fan assembly as required.
  12.  
  13. Install a new flange gasket and connect the exhaust pipe.
  14.  
  15. Connect the negative battery cable and check for exhaust leaks.
  16.  

1.5L And 1.8L Engine


Click image to see an enlarged view

Fig. Exploded view of the exhaust manifold -1.5L engine



Click image to see an enlarged view

Fig. Exhaust manifold exploded view-1.8L engine

  1. Disconnect battery negative cable.
  2.  
  3. Raise the vehicle and support safely.
  4.  
  5. Remove the exhaust pipe to exhaust manifold nuts and separate exhaust pipe. Discard gasket.
  6.  
  7. Lower vehicle.
  8.  
  9. Remove electric cooling fan assembly, if necessary.
  10.  
  11. If the oxygen sensor is located in the manifold, remove the sensor.
  12.  
  13. Disconnect necessary EGR components.
  14.  
  15. Remove outer exhaust manifold heat shield and engine hanger. Detach the electrical connector and remove the oxygen sensor.
  16.  
  17. Remove the exhaust manifold mounting bolts, the inner heat shield and the exhaust manifold.
  18.  

To install:

  1. Clean all gasket material from the mating surfaces and check the manifold for damage.
  2.  
  3. Using a new gasket, install the manifold. For 1.5L engines, tighten the nuts in a crisscross pattern to 13 ft. lbs. (18 Nm). For 1.8L engines, tighten the inner nuts in a crisscross pattern to 13 ft. lbs. (18 Nm) and tighten the two outer (larger) nuts to 22 ft. lbs. (30 Nm).
  4.  
  5. Install the heat shields.
  6.  
  7. Connect EGR components.
  8.  
  9. If removed, install the oxygen sensor.
  10.  
  11. Install the electric cooling fan assembly as required.
  12.  
  13. Install a new flange gasket and connect the exhaust pipe.
  14.  
  15. Connect the negative battery cable and check for exhaust leaks.
  16.  

2.0L (420a) Engine


Click image to see an enlarged view

Fig. Exploded view of the exhaust manifold and related components-2.0L (420A) engine


CAUTION
The air bag system must be disarmed before removing the exhaust manifold.

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine coolant.
  4.  
  5. Remove or disconnect the following:

    Air intake hose
     
    Upper radiator hose from the water outlet
     
    Air hose connection
     
    Engine control wiring harness from the rear of the engine
     
    Water pipe assembly
     
    Oil dipstick
     
    Upper heat shield
     
    Engine hanger
     
    Pulsed secondary air injection (check valve) valve from the exhaust pipe (manual transaxle only)
     
    Front exhaust pipe from the manifold
     
    Lower heat shield
     
    Exhaust manifold and gasket
     

  6.  

To install:

  1. Use a new gasket and install the exhaust manifold. Torque the nuts and bolts to 17 ft. lbs. (23 Nm).
  2.  
  3. Install the lower heat shield.
  4.  
  5. Use a new gasket and connect the front exhaust pipe to the manifold.
  6.  
  7. On vehicles with manual transaxles, connect the pulsed secondary air injection valve to the exhaust pipe.
  8.  
  9. Install or connect the following:

    Engine hanger
     
    Upper heat shield
     
    Dipstick and the water pipe
     

  10.  
  11. Attach the engine wiring harness to the rear of the engine.
  12.  
  13. Install or connect the following:

    Air hose and the upper radiator hose
     
    Air intake hose
     
    Negative battery cable
     

  14.  
  15. Refill the engine with coolant, start the engine and check for leaks.
  16.  

2.0L Engine
  1. Remove or disconnect the following:

    Negative battery cable
     
    Engine undercover
     
    Pressure hose clamp bolt
     
    Power steering pump bracket stay bolt
     
    Drive belt
     
    Power steering pump and bracket assembly and position it aside. Do NOT disconnect the fluid lines.
     
    Front exhaust pipe and gasket from the manifold. Discard the gasket.
     
    Exhaust manifold bracket -B- (see illustration)
     
    Heated Oxygen (HO 2 S) sensor
     
    Heat shield
     
    Exhaust manifold retainers and manifold
     
    Exhaust manifold gasket, and discard
     
    Exhaust manifold bracket -A- (see illustration)
     

  2.  

To install:

Click image to see an enlarged view

Fig. Exhaust manifold and related components-2.0L engine

  1. Clean all gasket material from the mating surfaces.
  2.  
  3. Install or connect the following:

    Exhaust manifold bracket -A-
     
    New gasket and exhaust manifold. Tighten the upper retainers to 20-24 ft. lbs. (27-33 Nm) and the lower retainers to 10-14 ft. lbs. (15-19 Nm).
     
    Heat shield
     
    HO 2 S
     
    Exhaust manifold bracket -B-
     
    Front exhaust pipe to the exhaust manifold, using a new gasket
     
    Power steering pump assembly
     
    Drive belt
     
    Power steering pump bracket stay bolt
     
    Pressure hose clamp bolt
     
    Engine undercover
     
    Negative battery cable
     

  4.  

2.4L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the heated oxygen sensor electrical connection. Remove the heated oxygen sensor.
  4.  
  5. Remove the exhaust manifold cover retaining screws. Remove the cover.
  6.  
  7. Remove the exhaust manifold bracket. Remove the lower heat shield.
  8.  
  9. Remove the exhaust manifold retaining bolts. Remove the exhaust manifold from the engine.
  10.  
  11. Discard the old gasket.

    Click image to see an enlarged view

    Fig. Exhaust manifold and related components-2002-2005 Eclipse 2.4L engine

  12.  

To install:

  1. Position a new exhaust manifold gasket to the mating surface of the cylinder.
  2.  
  3. Install the exhaust manifold to the engine. Torque the retaining bolts to specification.
  4.  
  5. Continue the installation in the reverse order of the removal procedure.
  6.  



Click image to see an enlarged view

Fig. Remove the exhaust pipe-to-exhaust manifold nuts



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Fig. Remove the hanger retaining bolt . . .



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Fig. . . . then separate the pipe from the manifold



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Fig. Remove the heat shield retaining bolts . . .



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Fig. . . . then remove the heat shield from the exhaust manifold



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Fig. Remove the exhaust manifold retaining nuts



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Fig. Remove the engine lifting eye from the manifold . . .



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Fig. . . . then remove the manifold from the cylinder head



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Fig. Remove the exhaust manifold gasket, thoroughly clean the mounting surfaces, and replace the gasket

  1. Disconnect battery negative cable.
  2.  
  3. Raise the vehicle and support safely.
  4.  
  5. Remove the exhaust pipe-to-exhaust manifold nuts, the hanger retaining bolt, then separate the exhaust pipe. Discard the gasket.
  6.  
  7. Remove the outer exhaust manifold heat shield and engine hanger.
  8.  
  9. Remove the exhaust manifold mounting nuts and the exhaust manifold from the engine.
  10.  

To install:

  1. Clean all gasket material from the mating surfaces and check the manifold for damage or cracking.
  2.  
  3. Install a new gasket and install the manifold. Tighten the nuts to in a crisscross pattern to 18-21 ft. lbs. (25-29 Nm).
  4.  
  5. Install the heat shields and tighten the mounting bolts 10 ft. lbs. (14 Nm).
  6.  
  7. Install a new flange gasket and connect the exhaust pipe. Tighten the mounting nuts to 32 ft. lbs. (44 Nm).
  8.  
  9. Connect the negative battery cable and check for exhaust leaks.
  10.  

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the heated oxygen sensor electrical connection. Remove the heated oxygen sensor.
  4.  
  5. Remove the exhaust manifold cover retaining screws. Remove the cover.
  6.  
  7. Remove the exhaust manifold bracket. Remove the lower heat shield.
  8.  
  9. Remove the exhaust manifold retaining bolts. Remove the exhaust manifold from the engine.
  10.  
  11. Discard the old gasket.

    Click image to see an enlarged view

    Fig. Exhaust manifold and related components-2004-2005 Galant 2.4L engine

  12.  

To install:

  1. Position a new exhaust manifold gasket to the mating surface of the cylinder.
  2.  
  3. Install the exhaust manifold to the engine. Torque the retaining bolts to specification.
  4.  
  5. Continue the installation in the reverse order of the removal procedure.
  6.  

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Remove the engine hanger.
  6.  
  7. Remove the exhaust manifold cover.
  8.  
  9. Remove the exhaust manifold mounting nuts and exhaust manifold.
  10.  
  11. Remove the exhaust manifold gasket, and discard.

    Click image to see an enlarged view

    Fig. Exhaust manifold and related components-2004-2005 Lancer 2.4L engine (except California)



    Click image to see an enlarged view

    Fig. Exhaust manifold and related components-2005-2005 Lancer 2.4L engine (California)

  12.  

To install:

  1. Clean all gasket material from the mating surfaces.
  2.  
  3. Install a new gasket and the exhaust manifold. Torque the manifold nuts to specification.
  4.  
  5. Install the exhaust manifold cover.
  6.  
  7. Install the engine hanger.
  8.  
  9. Install the air cleaner assembly.
  10.  
  11. Connect the negative battery cable.
  12.  

3.0L Engine


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Fig. Exploded view of the exhaust manifold and related components-3.0L SOHC engine



Click image to see an enlarged view

Fig. Exploded view of the exhaust manifold -3.0L DOHC engine


CAUTION
Do not attempt the work on the exhaust system until it has completely cooled.

  1. Disconnect battery negative cable.
  2.  
  3. Raise the vehicle and support safely.
  4.  
  5. Remove the exhaust pipe to exhaust manifold nuts and remove the front exhaust pipe.
  6.  
  7. Lower the vehicle.
  8.  
  9. If removing the front manifold, remove condenser electric cooling fan assembly.
  10.  
  11. For the DOHC engine, if removing the front manifold, remove the alternator and mounting bracket from the vehicle.
  12.  
  13. For the DOHC engine, separate the A/C compressor from the mounting bracket. Leaving the hoses connected, position the compressor aside.
  14.  
  15. If removing the front manifold, remove the oil dipstick and tube from the engine.
  16.  
  17. For the DOHC engine, if removing the front manifold, remove the heat protector.
  18.  
  19. If removing the rear manifold, disconnect the EGR tube.
  20.  
  21. For the SOHC engine, if removing the rear manifold, remove the intake plenum stay and the roll stopper bracket.
  22.  
  23. Unplug the electrical connector and remove the oxygen sensor.
  24.  
  25. Remove the exhaust manifold mounting bolts the manifold.
  26.  

To install:

  1. Clean all gasket material from the mating surfaces and check the manifold for damage.
  2.  
  3. Install a new gasket and install the manifold. Tighten the nuts in a crisscross pattern to 21 ft. lbs. (30 Nm) for the SOHC engine or to 14 ft. lbs. (19 Nm) for the DOHC engine.
  4.  
  5. Install the heat shields.
  6.  
  7. Connect the EGR tube and intake plenum stay and roll stopper bracket, if removed.
  8.  
  9. Install the oxygen sensor.
  10.  
  11. Install the electric cooling fan assembly, A/C compressor, dipstick tube and alternator, as required.
  12.  
  13. Install a new flange gasket and connect the exhaust pipe or converter assembly.
  14.  
  15. Install the drive belt(s) and adjust for proper tension.
  16.  
  17. Connect the negative battery cable and check for exhaust leaks.
  18.  

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Remove the exhaust manifold heat protector shields.
  6.  
  7. Remove the Oxygen sensor.
  8.  
  9. Remove the exhaust manifold mounting nuts and exhaust manifold(s).
  10.  
  11. Remove the exhaust manifold gasket(s), and discard.
  12.  
  13. Remove the engine hanger.
  14.  

To install:

  1. Install the engine hanger.
  2.  
  3. Clean all gasket material from the mating surfaces.
  4.  
  5. Install a new gasket and the exhaust manifold. Torque the manifold nuts in a crisscross pattern, starting from the inside and working outwards to 29-37 ft. lbs. (39-49 Nm).
  6.  
  7. Install the O 2 S sensor. Tighten to 29-37 ft. lbs. (39-49 Nm).
  8.  
  9. Install the exhaust manifold heat protector shields.
  10.  
  11. Install the air cleaner assembly.
  12.  
  13. Connect the negative battery cable.
  14.  

  1. Disconnect the negative battery cable. Remove the battery and battery tray.
  2.  
  3. Disconnect the front exhaust pipe. Remove the strut tower bar assembly.
  4.  
  5. Remove the air cleaner assembly. Remove the engine oil dipstick and dipstick tube assembly.
  6.  
  7. Remove the upper heat shield protector.
  8.  
  9. On the left side remove the front heated oxygen sensor, heat protector shield, and lower heat protector shield.
  10.  
  11. Remove the left exhaust manifold retaining bolts. Remove the manifold from the engine. Discard the gasket.
  12.  
  13. Remove the intake manifold plenum, if equipped with IMT system. Remove the EGR pipe.
  14.  
  15. On the right side remove the upper heat protector shield, front heat protector shield, and lower heat protector shield.
  16.  
  17. Remove the right exhaust manifold retaining bolts. Remove the manifold from the engine. Discard the gasket.

    Click image to see an enlarged view

    Fig. Exhaust manifold and related components-2004-2005 Eclipse 3.0L engine

  18.  

To install:

  1. Position a new exhaust manifold gasket to the mating surface of the cylinder.
  2.  
  3. Install the exhaust manifold to the engine. Torque the retaining bolts to specification.
  4.  
  5. Continue the installation in the reverse order of the removal procedure.
  6.  



Click image to see an enlarged view

Fig. Exploded view of the exhaust manifold and related components-1999-2003 3.0L engine

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Remove the exhaust manifold heat protector shields.
  6.  
  7. Remove the Oxygen (O 2 S sensor.
  8.  
  9. Remove the exhaust manifold mounting nuts and exhaust manifold(s).
  10.  
  11. Remove the exhaust manifold gasket(s), and discard.
  12.  
  13. Remove the engine hanger.
  14.  

To install:

  1. Install the engine hanger.
  2.  
  3. Clean all gasket material from the mating surfaces.
  4.  
  5. Install a new gasket and the exhaust manifold. Torque the manifold nuts in a crisscross pattern, starting from the inside and working outwards to 29-37 ft. lbs. (39-49 Nm).
  6.  
  7. Install the oxygen sensor. Tighten to 29-37 ft. lbs. (39-49 Nm).
  8.  
  9. Install the exhaust manifold heat protector shields.
  10.  
  11. Install the air cleaner assembly.
  12.  
  13. Connect the negative battery cable.
  14.  

3.5L Engine


Click image to see an enlarged view

Fig. Exhaust manifold exploded view-3.5L engine


CAUTION
Do not attempt the work on the exhaust system until it has completely cooled.

  1. Disconnect battery negative cable.
  2.  
  3. Raise the vehicle and support safely.
  4.  
  5. Remove the exhaust pipe to exhaust manifold nuts and remove the front exhaust pipe.
  6.  
  7. Lower the vehicle.
  8.  
  9. If removing the front manifold, remove the radiator and cooling fan assembly.
  10.  
  11. If removing the front manifold, remove the alternator.
  12.  
  13. Remove the heat protector(s).
  14.  
  15. If removing the rear manifold, disconnect the EGR tube.
  16.  
  17. Remove the exhaust manifold mounting bolts the manifold.
  18.  

To install:

  1. Clean all gasket material from the mating surfaces and check the manifold for damage.
  2.  
  3. Install a new gasket and install the manifold. Tighten the nuts in a crisscross pattern to 21 ft. lbs. (30 Nm).
  4.  
  5. Install the heat protector(s).
  6.  
  7. If installing the rear manifold, replace the gasket and connect the EGR tube.
  8.  
  9. If installing the front manifold, install the radiator and cooling fan assembly.
  10.  
  11. If installing the front manifold, install the alternator.
  12.  
  13. Install the drive belt(s) and adjust for proper tension.
  14.  
  15. Raise and safely support the vehicle securely on jackstands.
  16.  
  17. Install a new flange gasket and connect the exhaust pipe or converter assembly.
  18.  
  19. Lower the vehicle.
  20.  
  21. Connect the negative battery cable and check for exhaust leaks.
  22.  

3.8L Engine
Left Side
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine under cover. Remove the air cleaner intake duct assembly.
  4.  
  5. Remove the front heated oxygen sensor electrical connector. Remove the sensor.
  6.  
  7. Remove the rear heated oxygen sensor electrical connector. Remove the sensor.
  8.  
  9. Remove the heat protector shield.
  10.  
  11. Remove the front exhaust pipe connecting bolts. Remove and discard the gasket. Remove the exhaust manifold bracket.
  12.  
  13. Remove the exhaust manifold retaining bolts. Remove the manifold from the engine. Discard the gasket.
  14.  

To install:

  1. Position a new exhaust manifold gasket to the mating surface of the cylinder.
  2.  
  3. Install the exhaust manifold to the engine. Torque the retaining bolts to specification.
  4.  
  5. Continue the installation in the reverse order of the removal procedure.
  6.  

Right Side
  1. Disconnect the negative battery cable. Remove the battery and battery tray.
  2.  
  3. Remove the engine under cover. Remove the air cleaner intake duct assembly.
  4.  
  5. Remove the front exhaust pipe. Remove the center exhaust pipe.
  6.  
  7. Remove the strut tower bar assembly. Drain the engine coolant.
  8.  
  9. Remove the steering gear and linkage protector.
  10.  
  11. Remove the center under floor heat protector shield. Remove the exhaust manifold bracket.
  12.  
  13. Remove the front heated oxygen sensor electrical connector. Remove the sensor.
  14.  
  15. Remove the rear heated oxygen sensor electrical connector. Remove the sensor.
  16.  
  17. Remove the EGR pipe and gasket. Remove the upper and lower heat shield protector.
  18.  
  19. Remove the exhaust manifold retaining bolts. Remove the manifold from the engine. Discard the gasket.

    Click image to see an enlarged view

    Fig. Exhaust manifold and related components-2004-2005 Galant 3.8L engine (right side)

  20.  

To install:

  1. Position a new exhaust manifold gasket to the mating surface of the cylinder.
  2.  
  3. Install the exhaust manifold to the engine. Torque the retaining bolts to specification.
  4.  
  5. Continue the installation in the reverse order of the removal procedure.
  6.  

Evolution

The removal and installation procedure for the exhaust manifold is a part of the Turbocharger procedure, located in this section.

Non-Turbocharged Vehicles
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the battery negative cable.
  4.  
  5. Remove the exhaust pipe from the exhaust manifold.
  6.  
  7. Remove electric cooling fan assembly, if necessary. If removing the front manifold, remove the dipstick tube. If removing the front manifold from 3.0L DOHC engine, remove the alternator.
  8.  
  9. Disconnect the Exhaust Gas Recirculation (EGR) pipe.
  10.  
  11. Disconnect the electrical connector and remove the Heated Oxygen (HO 2 S) sensor.
  12.  
  13. Remove the exhaust manifold mounting bolts, the inner heat shield and the exhaust manifold.
  14.  

To install:

  1. Clean all gasket material from the mating surfaces.
  2.  
  3. Install a new gasket and install the manifold. Tighten the nuts in a crisscross pattern to 22 ft. lbs. (30 Nm).
  4.  
  5. Install the heat shields.
  6.  
  7. Connect the EGR pipe.
  8.  
  9. Install the HO 2 S sensor.
  10.  
  11. Install the electric cooling fan assembly, dipstick tube and alternator, as required.
  12.  
  13. Install a new flange gasket and connect the exhaust pipe.
  14.  
  15. Connect the negative battery cable and check for exhaust leaks.
  16.  

Turbocharged Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the engine coolant.
  6.  
  7. Remove the turbocharger assembly.
  8.  
  9. Remove the heat shield.
  10.  
  11. Remove the mounting nuts and remove the exhaust manifold. Note that the cone disc springs are installed at all lower mounting points.
  12.  

To install:

  1. Clean all gasket material from the mating surfaces.
  2.  
  3. Install new gaskets and install the manifold. Be sure all cone disc springs are in their original locations with the grooved side facing the nut. Tighten the manifold nuts using the following procedure:
    1. Tighten all but the outer two nuts to 22 ft. lbs. (30 Nm).
    2.  
    3. Tighten the outer two nuts to 34-38 ft. lbs. (47-53 Nm).
    4.  
    5. Loosen the outer two nuts, then tighten them to 22 ft. lbs. (30 Nm).
    6.  

  4.  
  5. Install the heat shield.
  6.  
  7. Install the turbocharger assembly.
  8.  
  9. Fill the cooling system.
  10.  
  11. Connect the negative battery cable and check for exhaust leaks.
  12.  

 
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