Mitsubishi Car 1999-05

Intake Manifold 1

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Disconnect battery negative cable.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove the air intake hoses.
  10.  
  11. Disconnect the accelerator cables from the throttle body.
  12.  
  13. Label and disconnect the vacuum hoses and harness connectors from the upper intake plenum.
  14.  
  15. Disconnect the clutch booster vacuum hose connection, if equipped.
  16.  
  17. Disconnect the Exhaust Gas Recirculation (EGR) components on California vehicles.
  18.  
  19. Remove the plenum retaining bracket.
  20.  
  21. Remove the plenum retaining nuts and bolts and remove the air intake plenum.
  22.  
  23. Disconnect the high pressure and return fuel hoses.
  24.  
  25. Remove the fuel injector connectors and the pressure regulator vacuum line.
  26.  
  27. Remove the fuel rail with the injectors attached.
  28.  
  29. Remove the timing belt upper cover.
  30.  
  31. Remove the intake manifold mounting nuts.
  32.  
  33. Remove the intake manifold.
  34.  

To install:

  1. Thoroughly clean the mating surfaces of the heads, intake manifold and air intake plenum.
  2.  
  3. Install new intake manifold gaskets to the heads with the adhesive side facing up.
  4.  
  5. Place the manifold on the heads and install the cone disc springs and/or lockwashers.
  6.  
  7. Lubricate the studs lightly with oil, then install the nuts following this procedure:
    1. Tighten the nuts on the front bank to 4-6 ft. lbs. (3-5 Nm).
    2.  
    3. Tighten the nuts on the rear bank to 14-17 ft. lb. (20-23 Nm).
    4.  
    5. Tighten the nuts on the front bank to 14-17 ft. lbs. (20-23 Nm).
    6.  
    7. Repeat Steps B and C.
    8.  

  8.  
  9. Install the timing belt upper cover.
  10.  
  11. Install the fuel rail assembly.
  12.  
  13. Connect the fuel injector connectors and the pressure regulator vacuum line.
  14.  
  15. Replace the O-ring and connect the fuel hoses.
  16.  
  17. Install the plenum. Tighten the retaining nuts and bolts evenly and gradually to 13 ft. lbs. (18 Nm).
  18.  
  19. Install the retaining bracket.
  20.  
  21. Connect EGR components on California vehicles.
  22.  
  23. Connect the upper intake harness connectors and vacuum hoses.
  24.  
  25. Connect and adjust the accelerator cables.
  26.  
  27. Install the air intake hoses.
  28.  
  29. Fill the system with coolant.
  30.  
  31. Connect the negative battery cable.
  32.  



Click image to see an enlarged view

Fig. Intake manifold plenum assembly-3.5L engine



Click image to see an enlarged view

Fig. Intake manifold and related components-3.5L engine

  1. Relieve the fuel system pressure.
    CAUTION
    Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  2.  
  3. Disconnect battery negative cable and drain the cooling system.
    CAUTION
    Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  4.  
  5. Remove the air intake hose(s).
  6.  
  7. Disconnect the accelerator control cables from the throttle body.
  8.  
  9. Tag and disconnect the vacuum hoses including the brake booster hose.
  10.  
  11. Tag and detach the wire harness connectors.
  12.  
  13. Disconnect the high pressure and return fuel hoses.
  14.  
  15. Disconnect EGR pipe and remove the EGR valve and EGR temperature sensor from the intake plenum assembly.
  16.  
  17. If equipped, remove the manifold pressure sensor.
  18.  
  19. Remove the plenum retaining bracket.
  20.  
  21. Remove the plenum retaining nuts and bolts and remove the air intake plenum from the intake manifold. Discard the gasket.
  22.  
  23. Remove the upper timing belt covers.
  24.  
  25. Remove the water pump stay bracket.
    NOTE
    It is not necessary to remove the fuel injectors from the intake unless the manifold assembly is being replaced.

  26.  
  27. Remove the fuel rail with the injectors attached.
  28.  
  29. Disconnect the coolant hoses from the intake manifold. Be sure to note the connections.
  30.  
  31. Remove the intake manifold mounting nuts and remove the intake manifold.
  32.  
  33. Clean the gasket mounting surfaces.
  34.  

To install:

  1. Check all items for cracks, clogging and warpage. Maximum warpage is 0.0059 inches (0.15mm). Replace any questionable parts.
  2.  
  3. Thoroughly clean and dry the mating surfaces of the heads, intake manifold and air intake plenum.
  4.  
  5. Install new intake manifold gaskets to the cylinder heads with the adhesive side facing up.
  6.  
  7. Place the manifold on the cylinder heads.
  8.  
  9. Lubricate the studs lightly with oil and install the nuts.
  10.  
  11. Tighten the mounting nuts as follows:
    1. Front bank nuts: 48-72 inch lbs. (5-8 Nm)
    2.  
    3. Rear bank nuts to: 14-17 ft. lbs. (20-23 Nm)
    4.  
    5. Front bank nuts to: 14-17 ft. lbs. (20-23 Nm)
    6.  

  12.  
  13. Using new clamps, connect the coolant hoses to the intake manifold.
  14.  
  15. Using new O-rings, install the fuel rail assembly, if removed. Tighten the mounting bolts to 7-9 ft. lbs. (10-13 Nm).
  16.  
  17. Install a new intake air plenum gasket and install the plenum. Tighten the retaining nuts and bolts evenly and gradually to 13 ft. lbs. (18 Nm).
  18.  
  19. Install the retaining bracket and tighten the retaining bolts to 13 ft. lbs. (18 Nm).
  20.  
  21. If removed, install the manifold pressure sensor.
  22.  
  23. Using a new gasket, install the EGR valve and tighten the bolts to 16 ft. lbs. (22 Nm).
  24.  
  25. Install the EGR temperature sensor and tighten the fitting to 7-9 ft. lbs. (10-12 Nm).
  26.  
  27. Connect the EGR pipe and tighten the fittings to 43 ft. lbs. (60 Nm).
  28.  
  29. Replace the O-ring and connect the high pressure fuel hose. Tighten the retaining bolts to 48 inch lbs. (5 Nm).
  30.  
  31. Using a new hose clamp, connect the fuel return hose.
  32.  
  33. Install the water pump stay bracket.
  34.  
  35. Install the upper timing belt covers.
  36.  
  37. Connect the harness connector and vacuum hoses.
  38.  
  39. Connect and adjust the accelerator cables.
  40.  
  41. Install the air intake hose(s).
  42.  
  43. Fill the system with coolant.
  44.  
  45. Connect the negative battery cable, run the vehicle until the thermostat opens, and fill the radiator completely.
  46.  
  47. Check and adjust the idle speed and ignition timing.
  48.  
  49. Once the vehicle has cooled, recheck the coolant level.
  50.  

1.5L Engine


Click image to see an enlarged view

Fig. Exploded view of the intake and exhaust manifold mounting-1.5L (4G15) engine

  1. Relieve the fuel system pressure.
  2.  


CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  1. Disconnect battery negative cable and drain the cooling system.
  2.  


CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Disconnect the upper radiator hose, heater hose and water bypass hose.
  2.  
  3. Remove the thermostat housing from intake manifold.
  4.  
  5. Disconnect the accelerator cable, breather hose and air intake hose.
  6.  
  7. Remove all vacuum hoses and pipes as necessary, including the brake booster vacuum line.
  8.  
  9. Remove the throttle body assembly.
  10.  
  11. Disconnect the high pressure fuel line and the fuel return hose.
  12.  
  13. Tag and detach the electrical connectors from the oxygen sensor, coolant temperature sensor, intake air temperature, idle speed control assembly, EGR temperature sensor, spark plug wires and distributor.
  14.  
  15. Remove the fuel rail, fuel injectors, pressure regulator and insulators.
  16.  
  17. Remove the EGR valve from the intake manifold.
  18.  
  19. Remove the intake manifold support bracket and remove the engine mount support bracket.
  20.  
  21. Remove the intake manifold mounting bolts and remove the intake manifold assembly.
  22.  

To install:

  1. Clean all gasket material from the cylinder head intake mounting surface and intake manifold assembly. Check both surfaces for cracks or other damage. Check the intake manifold water passages and jet air passages for clogging. Clean if necessary.
  2.  
  3. Using a straight edge, measure the distortion of the intake manifold-to-cylinder head. Total distortion or warpage should be 0.006 inches (0.15mm or less).
  4.  
  5. Install a new intake manifold gasket to the head and install the manifold. Torque the manifold in a crisscross pattern, starting from the inside and working outwards to 13 ft. lbs. (18 Nm).
  6.  
  7. Install the intake manifold support bracket and torque the mounting bolts to 16 ft. lbs. (22 Nm).
  8.  
  9. Install the engine mount support bracket and torque the mounting bolts to 26 ft. lbs. (36 Nm).
  10.  
  11. Using a new gasket, install the EGR valve and torque the mounting bolts to 15 ft. lbs. (21 Nm).
  12.  
  13. Using new insulators and O-rings, install the fuel delivery pipe, injectors and pressure regulator to the engine. Torque the retaining bolts to 7-9 ft. lbs. (10-14 Nm).
  14.  
  15. Attach the electrical connectors to the oxygen sensor, coolant temperature sensor, intake air temperature, idle speed control assembly, EGR temperature sensor, spark plug wires and distributor.
  16.  
  17. Using a new O-ring for the feed pipe and a new clamp for the return pipe, install the fuel hoses.
  18.  
  19. Install the throttle body assembly.
  20.  
  21. Install the vacuum hoses and pipes as necessary, including the brake booster vacuum line.
  22.  
  23. Install and adjust the accelerator cable. Install the breather and air intake hose.
  24.  
  25. Using a new gasket, install the thermostat housing to the intake manifold and tighten the mounting bolts to 13 ft. lbs. (18 Nm).
  26.  
  27. Connect the upper radiator hose, heater hose and water bypass hose. Be sure to use new hose clamps.
  28.  
  29. Fill the system with coolant.
  30.  
  31. Connect the negative battery cable, run the vehicle until the thermostat opens, fill the radiator completely.
  32.  
  33. Check and adjust the idle speed and ignition timing.
  34.  
  35. Once the vehicle has cooled, recheck the coolant level.
  36.  

  1. Relieve the fuel system pressure.
    CAUTION
    Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  2.  
  3. Disconnect battery negative cable and drain the cooling system.
    CAUTION
    Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  4.  
  5. Disconnect the upper radiator hose, heater hose and water bypass hose.
  6.  
  7. Remove the thermostat housing from intake manifold.
  8.  
  9. Disconnect the accelerator cable, breather hose and air intake hose.
  10.  
  11. Remove all vacuum hoses and pipes as necessary, including the brake booster vacuum line.
  12.  
  13. Remove the throttle body assembly.
  14.  
  15. Disconnect the high pressure fuel line and the fuel return hose.
  16.  
  17. Tag and detach the electrical connectors from the oxygen sensor, coolant temperature sensor, intake air temperature, idle speed control assembly, EGR temperature sensor, spark plug wires and distributor.
  18.  
  19. Remove the fuel rail, fuel injectors, pressure regulator and insulators.
  20.  
  21. Remove the EGR valve from the intake manifold.
  22.  
  23. Remove the intake manifold support bracket and remove the engine mount support bracket.
  24.  
  25. Remove the intake manifold mounting bolts and remove the intake manifold assembly.
  26.  

To install:

  1. Clean all gasket material from the cylinder head intake mounting surface and intake manifold assembly. Check both surfaces for cracks or other damage. Check the intake manifold water passages and jet air passages for clogging. Clean if necessary.
  2.  
  3. Using a straight edge, measure the distortion of the intake manifold-to-cylinder head. Total distortion or warpage should be 0.006 inches (0.15mm or less).
  4.  
  5. Install a new intake manifold gasket to the head and install the manifold. Torque the manifold in a crisscross pattern, starting from the inside and working outwards to 13 ft. lbs. (18 Nm).
  6.  
  7. Install the intake manifold support bracket and torque the mounting bolts to 16 ft. lbs. (22 Nm).
  8.  
  9. Install the engine mount support bracket and torque the mounting bolts to 26 ft. lbs. (36 Nm).
  10.  
  11. Using a new gasket, install the EGR valve and torque the mounting bolts to 15 ft. lbs. (21 Nm).
  12.  
  13. Using new insulators and O-rings, install the fuel delivery pipe, injectors and pressure regulator to the engine. Torque the retaining bolts to 7-9 ft. lbs. (10-14 Nm).
  14.  
  15. Attach the electrical connectors to the oxygen sensor, coolant temperature sensor, intake air temperature, idle speed control assembly, EGR temperature sensor, spark plug wires and distributor.
  16.  
  17. Using a new O-ring for the feed pipe and a new clamp for the return pipe, install the fuel hoses.
  18.  
  19. Install the throttle body assembly.
  20.  
  21. Install the vacuum hoses and pipes as necessary, including the brake booster vacuum line.
  22.  
  23. Install and adjust the accelerator cable. Install the breather and air intake hose.
  24.  
  25. Using a new gasket, install the thermostat housing to the intake manifold and tighten the mounting bolts to 13 ft. lbs. (18 Nm).
  26.  
  27. Connect the upper radiator hose, heater hose and water bypass hose. Be sure to use new hose clamps.
  28.  
  29. Fill the system with coolant.
  30.  
  31. Connect the negative battery cable, run the vehicle until the thermostat opens, and fill the radiator completely.
  32.  
  33. Check and adjust the idle speed and ignition timing.
  34.  
  35. Once the vehicle has cooled, recheck the coolant level.

    Click image to see an enlarged view

    Fig. Intake and exhaust manifold mounting-1.5L engine

  36.  

1.8L Engine


Click image to see an enlarged view

Fig. Exploded view of the intake manifold mounting-1993 1.8L engine



Click image to see an enlarged view

Fig. Exploded view of the intake manifold mounting-1994-00 1.8L engine

  1. Relieve the fuel system pressure.
  2.  


CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  1. Disconnect battery negative cable and drain the cooling system.
  2.  


CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Disconnect the accelerator cable and the air intake hose.
  2.  
  3. Tag and detach the electrical connectors from the oxygen sensor, coolant temperature sensor, idle speed control assembly, EGR temperature sensor, oil pressure switch, spark plug wires and distributor.
  4.  
  5. Disconnect the wiring from the throttle position sensor, fuel injectors and disconnect the ground cables.
  6.  
  7. Remove all vacuum hoses and pipes as necessary, including the brake booster and PCV vacuum lines.
  8.  
  9. Disconnect the upper radiator hose, heater hose and water bypass hose.
  10.  
  11. Disconnect the high pressure fuel line and the fuel return hose.
  12.  
  13. Remove the fuel rail, fuel injectors, pressure regulator and insulators.
  14.  
  15. Remove the intake manifold support bracket.
  16.  
  17. If the thermostat housing is preventing removal of the intake manifold, remove it.
  18.  
  19. Remove the intake manifold mounting bolts/nuts and remove the intake manifold assembly.
  20.  

To install:

  1. Clean all gasket material from the cylinder head intake mounting surface and intake manifold assembly. Check both surfaces for cracks or other damage. Check the intake manifold water passages and jet air passages for clogging. Clean if necessary.
  2.  
  3. Using a straight edge, measure the distortion of the intake manifold-to-cylinder head. Total distortion or warpage should be 0.006 inches (0.15mm or less).
  4.  
  5. Install a new intake manifold gasket to the head and install the manifold. Torque the manifold in a crisscross pattern, starting from the inside and working outwards to 14 ft. lbs. (20 Nm).
  6.  
  7. If removed, install the thermostat housing.
  8.  
  9. Install the intake manifold brace bracket.
  10.  
  11. Install the fuel delivery pipe, injectors and pressure regulator to the engine. Torque the retaining bolts to 108 inch lbs. (12 Nm).
  12.  
  13. Using a new O-ring for the feed pipe and a new clamp for the return pipe, install the fuel hoses.
  14.  
  15. Connect the upper radiator hose, heater hose and water bypass hoses.
  16.  
  17. Install the vacuum hoses and pipes as necessary. Be sure to connect the brake booster and PCV vacuum lines.
  18.  
  19. Connect the wiring to the throttle position sensor, fuel injectors and connect the ground cables.
  20.  
  21. Attach the electrical wiring to the oxygen sensor, coolant temperature sensor, idle speed control assembly, EGR temperature sensor, oil pressure switch, spark plug wires and distributor.
  22.  
  23. Connect and adjust the accelerator cable and install the air intake hose.
  24.  
  25. Fill the system with coolant.
  26.  
  27. Connect the negative battery cable, run the vehicle until the thermostat opens, fill the radiator completely.
  28.  
  29. Check and adjust the idle speed and ignition timing.
  30.  
  31. Once the vehicle has cooled, recheck the coolant level.
  32.  

  1. Relieve the fuel system pressure.
    CAUTION
    Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  2.  
  3. Disconnect battery negative cable and drain the cooling system.
    CAUTION
    Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  4.  
  5. Disconnect the accelerator cable and the air intake hose.
  6.  
  7. Tag and detach the electrical connectors from the oxygen sensor, coolant temperature sensor, idle speed control assembly, EGR temperature sensor, oil pressure switch, spark plug wires and distributor.
  8.  
  9. Disconnect the wiring from the throttle position sensor, fuel injectors and disconnect the ground cables.
  10.  
  11. Remove all vacuum hoses and pipes as necessary, including the brake booster and PCV vacuum lines.
  12.  
  13. Disconnect the upper radiator hose, heater hose and water bypass hose.
  14.  
  15. Disconnect the high pressure fuel line and the fuel return hose.
  16.  
  17. Remove the fuel rail, fuel injectors, pressure regulator and insulators.
  18.  
  19. Remove the intake manifold support bracket.
  20.  
  21. If the thermostat housing is preventing removal of the intake manifold, remove it.
  22.  
  23. Remove the intake manifold mounting bolts/nuts and remove the intake manifold assembly.
  24.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the intake manifold mounting-1.8L engine

  1. Clean all gasket material from the cylinder head intake mounting surface and intake manifold assembly. Check both surfaces for cracks or other damage. Check the intake manifold water passages and jet air passages for clogging. Clean if necessary.
  2.  
  3. Using a straight edge, measure the distortion of the intake manifold-to-cylinder head. Total distortion or warpage should be 0.006 inches (0.15mm or less).
  4.  
  5. Install a new intake manifold gasket to the head and install the manifold. Torque the manifold in a crisscross pattern, starting from the inside and working outwards to 14 ft. lbs. (20 Nm).
  6.  
  7. If removed, install the thermostat housing.
  8.  
  9. Install the intake manifold brace bracket.
  10.  
  11. Install the fuel delivery pipe, injectors and pressure regulator to the engine. Torque the retaining bolts to 108 inch lbs. (12 Nm).
  12.  
  13. Using a new O-ring for the feed pipe and a new clamp for the return pipe, install the fuel hoses.
  14.  
  15. Connect the upper radiator hose, heater hose and water bypass hoses.
  16.  
  17. Install the vacuum hoses and pipes as necessary. Be sure to connect the brake booster and PCV vacuum lines.
  18.  
  19. Connect the wiring to the throttle position sensor, fuel injectors and connect the ground cables.
  20.  
  21. Attach the electrical wiring to the oxygen sensor, coolant temperature sensor, idle speed control assembly, EGR temperature sensor, oil pressure switch, spark plug wires and distributor.
  22.  
  23. Connect and adjust the accelerator cable and install the air intake hose.
  24.  
  25. Fill the system with coolant.
  26.  
  27. Connect the negative battery cable, run the vehicle until the thermostat opens, and fill the radiator completely.
  28.  
  29. Check and adjust the idle speed and ignition timing.
  30.  
  31. Once the vehicle has cooled, recheck the coolant level.
  32.  

2.0L And 2.4L Engines
  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system into a suitable container.
  6.  
  7. For 2.0L non-turbo engines, if equipped, remove the auto-cruise reservoir.
  8.  
  9. For 2.0L turbo and 2.4L engines, disconnect the positive cable, then remove the battery.
  10.  
  11. Disconnect the air intake and breather hoses.
  12.  
  13. Detach the accelerator cable connection.

    Click image to see an enlarged view

    Fig. Remove the accelerator cable connection

  14.  
  15. For 2.0L non-turbo engines, detach the connectors from the following components:
    1. MAP sensor

      Click image to see an enlarged view

      Fig. Detach the MAP sensor electrical connector

    2.  
    3. Charge temperature sensor

      Click image to see an enlarged view

      Fig. Unplug the charge air temperature electrical connector

    4.  
    5. Throttle position sensor
    6.  
    7. AIS sensor
    8.  

  16.  
  17. For 2.0L turbo and 2.4L engines, detach the connectors from the following components:
    1. Fuel injectors
    2.  
    3. Ignition coil
    4.  
    5. Manifold differential pressure sensor connector
    6.  
    7. Capacitor connector
    8.  
    9. Throttle position sensor
    10.  
    11. Knock sensor
    12.  
    13. Engine coolant temperature sensor
    14.  
    15. IAC motor
    16.  
    17. Camshaft position sensor
    18.  
    19. Crankshaft position sensor
    20.  
    21. A/C compressor
    22.  

  18.  
  19. Remove the control wiring harness clip.
  20.  
  21. Unplug the vacuum hose connection.
  22.  
  23. Unfasten the retainer, then remove the control wiring harness.

    Click image to see an enlarged view

    Fig. Unfasten the bolt, then position the control wiring harness aside

  24.  
  25. For 2.0L non-turbo engines, detach the alternator wiring harness connector.
  26.  
  27. Disconnect the PCV hose assembly and the brake booster vacuum hose connection.

    Click image to see an enlarged view

    Fig. Unfasten the hose retaining clamp . . .



    Click image to see an enlarged view

    Fig. . . . then disconnect the brake vacuum hose connection

  28.  
  29. For 2.0L turbo and 2.4L engines, detach the spark plug cable connection and fuel return hose connection.
  30.  
  31. For 2.0L non-turbo engines, detach the EGR pipe connection.

    Click image to see an enlarged view

    Fig. Unfasten the retaining bolts, and separate the EGR pipe connection

  32.  
  33. For 2.4L engines, remove the evaporative emission purge solenoid valve connector.
  34.  
  35. For 2.0L turbo and 2.4L engines, disconnect the following:
    1. Vacuum hose connection and vacuum pipe.
    2.  
    3. Brake booster vacuum hose connection.
    4.  
    5. Heater hose connections.
    6.  

  36.  
  37. As outlined in Section 5, disconnect the high-pressure fuel hose connection.
  38.  
  39. If equipped, remove the intake manifold stay.
  40.  
  41. Remove the engine hanger.
  42.  
  43. For 2.0L non-turbo engine, perform the following:
    1. Detach the injector connector, then remove the throttle body from the vehicle.
    2.  

  44.  
  45. Unfasten the retaining bolts, remove the intake manifold plenum, then remove and discard the plenum gasket.

    Click image to see an enlarged view

    Fig. Unfasten the plenum-to-lower manifold retaining bolts . . .



    Click image to see an enlarged view

    Fig. . . . then remove the upper intake manifold from the vehicle



    Click image to see an enlarged view

    Fig. Remove the intake plenum gaskets and replace with new ones during installation

  46.  
  47. Remove the fuel rail, fuel injector and pressure regulator assembly, as outlined in Section 5 of this manual.
  48.  
  49. If equipped, remove the insulators.
  50.  
  51. For the 2.0L turbo and 2.4L engines perform the following:
    1. Ignition power transistor
    2.  
    3. Ignition coil
    4.  
    5. EGR valve
    6.  
    7. Intake manifold stay
    8.  
    9. Engine hanger
    10.  

  52.  
  53. Unfasten the retaining bolts, then remove the intake manifold from the vehicle. Remove and discard the gasket.

    Click image to see an enlarged view

    Fig. Use a ratchet with an extension to remove the rear intake manifold mounting bolts



    Click image to see an enlarged view

    Fig. Remove the remaining intake manifold mounting bolts . . .



    Click image to see an enlarged view

    Fig. . . . then remove the intake manifold from the vehicle



    Click image to see an enlarged view

    Fig. Remove and discard the intake manifold gaskets, and thoroughly clean the mating surfaces

  54.  
  55. For 2.0L turbo engines, perform the following, if replacing the intake manifold:
    1. Remove the manifold differential pressure sensor.
    2.  
    3. Remove the charge air cooler fitting.
    4.  
    5. Remove the throttle body from the vehicle.
    6.  

  56.  
  57. For 2.4L engines, perform the following if replacing the intake manifold:
    1. Remove the throttle body.
    2.  
    3. Remove the EGR valve.

      Click image to see an enlarged view

      Fig. Exploded view of the intake plenum, manifold and related components-1999 2.0L non-turbo engines



      Click image to see an enlarged view

      Fig. Exploded view of the intake manifold and related components-1999 2.0L turbo engine



      Click image to see an enlarged view

      Fig. Exploded view of the intake manifold and related components-1999 2.4L engine

    4.  

  58.  

To install:

  1. Position a new gasket, then install the intake manifold. Tighten the retaining bolts to the specifications shown in the accompanying figures. Use a crisscross pattern starting from the center and work outwards.
  2.  
  3. Install new O-rings, then install the fuel rail assembly.
  4.  
  5. Place a new plenum gasket on the manifold, then install the intake manifold plenum. Tighten the bolts to the specifications shown in the accompanying figure.
  6.  
  7. Install the remaining components in the reverse order of the removal procedure.
  8.  
  9. Attach or install all hoses, cables and electrical connectors that were removed or disconnected during the removal procedure.
  10.  
  11. Fill the system with coolant.
  12.  
  13. Connect the negative battery cable, run the vehicle until the thermostat opens, and fill the radiator completely. Check for leaks.
  14.  
  15. Adjust the accelerator cable. Check and adjust the idle speed as required.
  16.  
  17. Once the vehicle has cooled, recheck the coolant level.
  18.  

2.0L Engine
  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable and drain the cooling system.
  4.  
  5. Remove the air cleaner assembly.
  6.  
  7. Remove the throttle body.
    NOTE
    If the throttle body uses a resin cover, do not loosen the retaining screws for the resin cover of the throttle body assembly. If these screws are loosened, the sensor incorporated in the resin cover becomes misaligned and the throttle body can not function properly.

  8.  
  9. Remove the Exhaust Gas Recirculation (EGR) valve and gasket.
  10.  
  11. Remove the fuel rail and injector assembly.
  12.  
  13. Remove the bracket and the engine hanger.
  14.  
  15. Remove the Manifold Differential Pressure (MDP) sensor and O-ring.
  16.  
  17. Remove the intake manifold stay bracket.
  18.  
  19. Remove the intake manifold bolt and manifold.
  20.  
  21. Remove the intake manifold gasket and discard.

    Click image to see an enlarged view

    Fig. Intake manifold and related components-2.0L engine

  22.  

To install:

  1. Clean all gasket material from the cylinder head intake mounting surface and intake manifold assembly.
  2.  
  3. Install the intake manifold, using a new gasket. Torque the manifold in a crisscross pattern, starting from the inside and working outwards to 12-16 ft. lbs. (16-22 Nm).
  4.  
  5. Install the intake manifold stay.
  6.  
  7. Install the throttle body stay.
  8.  
  9. Install the engine hanger.
  10.  
  11. Install the EGR valve and gasket.
  12.  
  13. Install the vacuum hose and pipe assembly.
  14.  
  15. Connect the brake booster vacuum hose connection.
  16.  
  17. Connect the vacuum pipe.
  18.  
  19. Connect the auto cruise vacuum hose connection.
  20.  
  21. Install the MDP sensor.
  22.  
  23. Install the fuel rail assembly.
  24.  
  25. Install the throttle body.
  26.  
  27. Install the air cleaner assembly.
  28.  
  29. Fill the system with coolant.
  30.  
  31. Connect the negative battery cable.
  32.  
  33. Connect the scan tool to the data link connector. To prevent damage to the scan tool be sure that the ignition switch is in the LOCK position before connecting the scan tool.
  34.  
  35. Turn the ignition switch to the ON position.
  36.  
  37. Select -check mode- from the menu screen.
  38.  
  39. Select -erase memory- from the menu screen.
  40.  
  41. Initialize the learning value.
  42.  
  43. After initialization complete the idle learning procedure.
    NOTE
    This procedure must be performed when the PCM is replaced, or when the learning value is initialized, as the idling is not stabilized because the learning value in the MFI engine is not completed.

  44.  
  45. Start the engine. Allow the coolant temperature to reach 176 degrees or more.
  46.  
  47. Stop the engine and place the ignition switch in the LOCK position.
  48.  
  49. After ten seconds, restart the engine.
  50.  
  51. For ten minutes carry out the idling procedure below to confirm that the engine has normal idling.
    NOTE
    If the engine stalls during idling, check the throttle valve of the throttle body for dirt. Correct and perform the procedure again.



    Position the transaxle selector lever in the -P- range
     
    The engine fan is not to be operated
     
    The engine coolant temperature should be 176 degrees or more
     

  52.  

2.4L (4g69) Engine
  1. Relieve the fuel system pressure. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly. Drain the cooling system. Remove the battery.
    NOTE
    Do not loosen the retaining screws for the resin cover of the throttle body assembly. If these screws are loosened, the sensor incorporated in the resin cover becomes misaligned and the throttle body can not function properly.

  4.  
  5. Disconnect the accelerator cable connection, throttle position sensor connector and water return hose connection
  6.  
  7. Remove the throttle body bracket. Remove the throttle body retaining bolts. Remove the throttle body. Discard the gasket.
  8.  
  9. Remove the delivery pipe and injector assembly.
  10.  
  11. Disconnect the EVAP purge solenoid valve connector, the evaporative emission purge hose connection and the EGR valve connector.
  12.  
  13. Disconnect the MAP sensor connector, brake booster vacuum hose connection, pressure hose clamp and knock sensor connector bracket.
  14.  
  15. Disconnect the harness clamp bracket and harness clamp. Remove the engine oil dipstick and tube assembly. Disconnect the lower radiator hose. Remove the thermostat case assembly, resonator and gasket.
  16.  
  17. Remove the EGR valve and gasket. Remove the harness clamp bracket, EVAP purge solenoid valve and brake booster vacuum pipe.
  18.  
  19. Remove the brake booster vacuum hose and MAP sensor. Remove the intake manifold bracket.
  20.  
  21. Remove the intake manifold retaining bolts. Remove the intake manifold from the engine. Discard the gasket.

    Click image to see an enlarged view

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

  22.  

To install:

Click image to see an enlarged view

Fig. Thermostat case assembly sealant application-2004-2005 Galant and 2004-2005 Lancer 2.4L engine

  1. Be sure to use a new intake manifold gasket. Position the gasket on the engine.
  2.  
  3. Install the intake manifold. Torque the retaining bolts to specification.
  4.  
  5. When installing the thermostat case assembly be sure to apply a bead of sealant, part number 8672 or equivalent, to the cylinder head mating surface of the case assembly.
    NOTE
    Be sure to assemble the components with 15 minutes of applying the sealant to the surfaces.

  6.  
  7. Continue the installation in the reverse order of the removal procedure.
    NOTE
    Be sure to install the throttle body gasket in the proper direction. If this gasket is not installed correctly, poor engine idling may result.

  8.  
  9. Complete the vehicle initialization procedure.
    NOTE
    To complete the initialization procedure the following tools are needed. MB991958 scan tool, MB991824 VCI, MB991827 MUT III USB cable, MB991910 MUT III Main harness -A-

  10.  
  11. Connect the scan tool to the data link connector. To prevent damage to the scan tool be sure that the ignition switch is in the LOCK position before connecting the scan tool.
  12.  
  13. Turn the ignition switch to the ON position.
  14.  
  15. Select -check mode- from the menu screen.
  16.  
  17. Select -erase memory- from the menu screen.
  18.  
  19. Initialize the learning value.
  20.  
  21. After initialization complete the idle learning procedure.
    NOTE
    This procedure must be performed when the PCM is replaced, or when the learning value is initialized, as the idling is not stabilized because the learning value in the MFI engine is not completed.

  22.  
  23. Start the engine. Allow the coolant temperature to reach 176 degrees or more.
  24.  
  25. Stop the engine and place the ignition switch in the LOCK position.
  26.  
  27. After ten seconds, restart the engine.
  28.  
  29. For ten minutes carry out the idling procedure below to confirm that the engine has normal idling.
    NOTE
    If the engine stalls during idling, check the throttle valve of the throttle body for dirt. Correct and perform the procedure again.



    Position the transaxle selector lever in the -P- range
     
    The engine fan is not to be operated
     
    The engine coolant temperature should be 176 degrees or more
     

  30.  

 
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