Mitsubishi Car 1999-05

Intake Manifold 2

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Removal & Installation



2.4L Engine
  1. Relieve the fuel system pressure.
  2.  
  3. Remove the battery.
  4.  
  5. Drain the engine coolant.
  6.  
  7. Remove or disconnect the following:

    Accelerator cable
     
    Air intake hose
     
    Ignition coil and the module wiring connectors
     
    Manifold Absolute Pressure (MAP) sensor
     
    Condenser
     
    Throttle Position (TP) sensor and the Idle Air Control (IAC) motor connectors
     
    Heated Oxygen (HO 2 S) sensor connector
     
    Crankshaft Position (CKP) sensor connector
     
    Air conditioning compressor connector
     
    Engine control wiring harness bracket and position the harness out of the way
     
    Vacuum hoses, label for reference
     
    Spark plug wires from the ignition coil
     
    Fuel lines from the fuel rail
     
    Heater hoses
     
    Fuel rail assembly
     
    Ignition coil and module
     
    Exhaust Gas Recirculation (EGR) valve assembly
     
    Intake manifold stay and the engine hanger
     
    Intake manifold

    Click image to see an enlarged view

    Fig. Intake manifold and related components-2002-2003 Eclipse and Galant 2.4L engine

     

  8.  

To install:

  1. Install or connect the following:

    Intake manifold. Torque the intake manifold bolts to 15 ft. lbs. (20 Nm).
     
    Intake manifold stay and the engine hanger. Torque the mounting bolts to 19-24 ft. lbs. (26-33 Nm).
     
    EGR assembly
     
    Ignition coil and module
     
    Fuel rail and insulators and reconnect the high-pressure fuel hose
     
    Heater hoses and fuel lines
     
    Spark plug wires to the coil towers
     
    Vacuum hoses
     
    Engine harness in the proper position
     
    MAP sensor
     
    TP sensor and the IAC motor connectors
     
    HO 2 S
     
    Ignition condenser
     
    Accelerator cable, adjust
     
    Battery
     

  2.  
  3. Refill the engine with coolant.
  4.  

  1. Relieve the fuel system pressure. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly. Drain the cooling system.
  4.  
  5. Disconnect the accelerator cable connection, throttle position sensor connector and idle air control motor connector. Remove the thermostat case assembly.
  6.  
  7. Disconnect the vacuum hose connection. Disconnect the water hose connection.
  8.  
  9. Remove the throttle body bracket. Remove the throttle body retaining bolts. Remove the throttle body. Discard the gasket.
  10.  
  11. Disconnect the hose connection, brake booster vacuum hose connection, ignition coil connector and injector connector.
  12.  
  13. Disconnect the manifold absolute pressure sensor connector, EVAP solenoid valve connector, EGR vacuum regulator solenoid valve connector and the high pressure hose connection.
  14.  
  15. Disconnect the fuel return hose connection. Remove the oil dipstick and tube assembly. Disconnect the pressure hose connection. Remove the PCV hose.
  16.  
  17. Remove the fuel return pipe, fuel hose, fuel injector rail, injector and pressure regulator.
  18.  
  19. Remove the vacuum pipe and EGR valve.
  20.  
  21. Remove the intake manifold retaining bolts. Remove the intake manifold from the engine. Remove and discard the gasket.

    Click image to see an enlarged view

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

  22.  

To install:

  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. 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.

  6.  



Click image to see an enlarged view

Fig. Detach the A/C temp electrical connector



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Fig. Unplug the connector from the Throttle Position (TP) sensor



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Fig. Detach the connectors from all of the fuel injectors



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Fig. Unplug the main engine harness junction electrical connector



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Fig. Detach the Camshaft Position (CMP) sensor connector



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Fig. Unplug the connector from the Manifold Absolute Pressure (MAP) sensor



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Fig. Detach the connector for the Idle Air Control (IAC) motor



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Fig. Remove the engine harness retaining bracket bolts, then move the harness out of the way



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Fig. Remove the accelerator cable end from the throttle lever



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Fig. Remove the accelerator cable bracket retaining bolts . . .



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Fig. . . . then position the accelerator cable out of the way



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Fig. Disconnect the EGR hose and the three vacuum hoses on the back of the intake manifold



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Fig. Remove the hose shown here from the throttle body



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Fig. Remove the brake booster vacuum hose from the back of the intake manifold



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Fig. Remove the fuel feed line-to-fuel rail retaining fitting bolts . . .



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Fig. . . . then remove the fuel feed line from the fuel injector rail



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Fig. From underneath the vehicle, remove the two intake manifold support bracket bolts



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Fig. Remove the intake manifold retaining bolts . . .



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

  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, breather hose and air intake hose.
  6.  
  7. Disconnect the coolant hose from the throttle housing.
  8.  
  9. Detach the vacuum connection at the power brake booster and the PCV valve if still connected. Disconnect all remaining vacuum hoses and pipes as necessary.
    CAUTION
    Fuel injection systems remain under pressure after the engine has been turned OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  10.  
  11. Disconnect the high pressure fuel line, fuel return hose and remove throttle control cable brackets.
  12.  
  13. Tag and unplug the electrical connectors from the coolant temperature sensor, coolant temperature gauge, IAC valve, ignition coil, EGR temperature sensor, knock sensor, oxygen sensor, throttle position sensor, distributor, A/C temperature sensor, fuel injectors and ignition power transistor. Position the engine wiring harness aside.
  14.  
  15. Label and disconnect the spark plug wires from the spark plugs.
  16.  
  17. Remove the intake manifold stay bracket.
  18.  
  19. Remove the intake manifold mounting bolts and remove the intake manifold assembly. Disassemble manifold on a work bench as required.
  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. Assemble the intake manifold assembly using all new gaskets.
  4.  
  5. Position a new intake manifold gasket on the head, then install the manifold. Torque the manifold in a crisscross pattern, starting from the inside and working outwards to 15 ft. lbs. (20 Nm) for bolts and 15 ft. lbs. (20 Nm) for nuts.
  6.  
  7. Install the fuel delivery pipe, injectors and pressure regulator to the engine. Torque the retaining bolts to 4 ft. lbs. (6 Nm).
  8.  
  9. Install the intake manifold brace bracket and tighten bolts to 21 ft. lbs. (29 Nm).
  10.  
  11. Connect or install all hoses, cables and electrical connectors that were removed or disconnected during the removal procedure.
  12.  
  13. Fill the system with coolant.
  14.  
  15. Connect the negative battery cable, run the vehicle until the thermostat opens, and fill the radiator completely.
  16.  
  17. Adjust the accelerator cable. Check and adjust the idle speed and ignition timing.
  18.  
  19. Once the vehicle has cooled, recheck the coolant level.
  20.  

  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.
  22.  

To install:

  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.  

3.0L & 3.5L Engines


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Fig. Exploded view of air intake plenum assembly-3.0L DOHC engine



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Fig. Intake manifold and related components-3.0L DOHC engine



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Fig. Exploded view of air intake plenum assembly-3.0L SOHC engine



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Fig. Exploded view of the intake manifold mounting-3.0L SOHC engine



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Fig. Exploded view of air intake plenum assembly-3.5L engine



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Fig. Exploded view of the intake manifold mounting-3.5L 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. Remove the air intake hose(s).
  2.  
  3. Disconnect the accelerator control cables from the throttle body.
  4.  
  5. Tag and disconnect the vacuum hoses including the brake booster hose.
  6.  
  7. Tag and detach the wire harness connectors.
  8.  
  9. Disconnect the high pressure and return fuel hoses.
  10.  
  11. Disconnect EGR pipe and remove the EGR valve and EGR temperature sensor from the intake plenum assembly.
  12.  
  13. If equipped, remove the manifold pressure sensor.
  14.  
  15. Remove the plenum retaining bracket.
  16.  
  17. Remove the plenum retaining nuts and bolts and remove the air intake plenum from the intake manifold. Discard the gasket.
  18.  
  19. Remove the upper timing belt covers.
  20.  
  21. Remove the water pump stay bracket.
  22.  


NOTE
It is not necessary to remove the fuel injectors from the intake unless the manifold assembly is being replaced.

  1. Remove the fuel rail with the injectors attached.
  2.  
  3. Disconnect the coolant hoses from the intake manifold. Be sure to note the connections.
  4.  
  5. Remove the intake manifold mounting nuts and remove the intake manifold.
  6.  
  7. Clean the gasket mounting surfaces.
  8.  

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. For vehicles produced up to and including November of 1993, tighten the mounting nuts as follows:
  12.  

  1. Front bank nuts: 27-43 inch lbs. (3-5 Nm)
  2.  
  3. Rear bank nuts: 9-11 ft. lbs. (12-15 Nm)
  4.  
  5. Front bank nuts: 9-11 ft. lbs. (12-15 Nm)
  6.  

  1. For vehicles produced after November of 1993, tighten the mounting nuts as follows:
  2.  

  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.  

  1. Using new clamps, connect the coolant hoses to the intake manifold.
  2.  
  3. Using new O-rings, install the fuel rail assembly, if removed. Tighten the mounting bolts to 7-9 ft. lbs. (10-13 Nm).
  4.  
  5. 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).
  6.  
  7. Install the retaining bracket and tighten the retaining bolts to 13 ft. lbs. (18 Nm).
  8.  
  9. If removed, install the manifold pressure sensor.
  10.  
  11. Using a new gasket, install the EGR valve and tighten the bolts to 16 ft. lbs. (22 Nm).
  12.  
  13. Install the EGR temperature sensor and tighten the fitting to 7-9 ft. lbs. (10-12 Nm).
  14.  
  15. Connect the EGR pipe and tighten the fittings to 43 ft. lbs. (60 Nm).
  16.  
  17. Replace the O-ring and connect the high pressure fuel hose. Tighten the retaining bolts to 48 inch lbs. (5 Nm).
  18.  
  19. Using a new hose clamp, connect the fuel return hose.
  20.  
  21. Install the water pump stay bracket.
  22.  
  23. Install the upper timing belt covers.
  24.  
  25. Connect the harness connector and vacuum hoses.
  26.  
  27. Connect and adjust the accelerator cables.
  28.  
  29. Install the air intake hose(s).
  30.  
  31. Fill the system with coolant.
  32.  
  33. Connect the negative battery cable, run the vehicle until the thermostat opens, fill the radiator completely.
  34.  
  35. Check and adjust the idle speed and ignition timing.
  36.  
  37. Once the vehicle has cooled, recheck the coolant level.
  38.  

 
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