Mitsubishi Car 1999-05

Intake Manifold 3

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Removal & Installation



3.0L Engine
  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable and drain the cooling system.
  4.  
  5. Remove both the front and rear intake manifold plenum stay brackets.
  6.  
  7. Remove the EGR valve and gasket.
  8.  
  9. Remove the EGR pipe and gasket.
  10.  
  11. Remove the Manifold Absolute Pressure (MAP) sensor.
  12.  
  13. Remove the throttle body and gasket.
  14.  
  15. If equipped with an induction control valve, remove the following:

    Induction control valve assembly
     
    Intake manifold upper
     
    Intake manifold plenum gasket
     

  16.  
  17. If NOT equipped with an induction control valve, remove the following:

    Intake manifold plenum
     
    Intake manifold plenum gasket
     

  18.  
  19. Disconnect the fuel injector harness.
  20.  
  21. Remove the fuel rail and injectors assembly, along with the insulators.
  22.  
  23. Remove the intake manifold mounting nuts and remove the intake manifold and gaskets.
  24.  
  25. Clean the gasket mounting surfaces.

    Click image to see an enlarged view

    Fig. Intake manifold and related components-2002-2003 Eclipse and Galant 3.0L engine

  26.  

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 cylinder heads with the adhesive side facing up.
  4.  
  5. Place the manifold on the cylinder heads.
  6.  
  7. Lubricate the studs lightly with oil and install the nuts.
  8.  
  9. Tighten the mounting nuts as follows:
    1. Right bank nuts: 44-70 inch lbs. (5-8 Nm).
    2.  
    3. Left bank nuts: 21-23 ft. lbs. (15-17 Nm).
    4.  
    5. Right bank nuts: 21-23 ft. lbs. (15-17 Nm).
    6.  
    7. Left bank nuts: 21-23 ft. lbs. (15-17 Nm).
    8.  
    9. Right bank nuts: 21-23 ft. lbs. (15-17 Nm).
    10.  

  10.  
  11. Using new O-rings, install the fuel rail and injectors assembly.
  12.  
  13. Connect the fuel injector wiring harness.
  14.  
  15. If equipped with an induction control valve, install the following:

    Intake manifold plenum gasket
     
    Intake manifold upper. Tighten retaining nuts to 12-14 ft. lbs. (16-20 Nm).
     
    Install the induction control valve gasket. Apply sealant to the gasket surface and install while the sealant is still wet (within 15 minutes).
     
    Induction control valve assembly. Tighten fasteners to 71-89 inch lbs. (8-10 Nm).
     

  16.  
  17. If NOT equipped with an induction control valve, install the following:

    Intake manifold plenum gasket
     
    Intake manifold plenum. Tighten retaining nuts to 12-14 ft. lbs. (16-20 Nm).
     

  18.  
  19. Install a new throttle body gasket and install the throttle body assembly.
  20.  
  21. Install the MAP sensor.
  22.  
  23. Install the EGR pipe and tighten the fittings to 12-14 ft. lbs. (16-20 Nm).
  24.  
  25. Install the EGR valve, using a new gasket. Tighten the bolts to 16 ft. lbs. (22 Nm).
  26.  
  27. Install the front and rear intake manifold plenum stay brackets.
  28.  
  29. Fill the system with coolant.
  30.  
  31. Connect the negative battery cable.
  32.  

  1. Relieve the fuel system pressure. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly. Drain the cooling system.
  4.  
  5. Remove the intake manifold plenum assembly.
  6.  
  7. Disconnect the injector connector wiring assembly, high pressure hose connection, O-ring and fuel return hose.
  8.  
  9. Disconnect the vacuum hose connection. Remove the fuel rail, injector and fuel pressure regulator.
  10.  
  11. Remove the PCV hose connection. Remove the timing belt front upper cover and right bracket.
  12.  
  13. Remove the intake manifold retaining bolts. Remove the intake manifold from the engine. Discard the gaskets.

    Click image to see an enlarged view

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

  14.  

To install:

  1. Be sure to use a new intake manifold gasket. Position the gasket on the engine.

    Click image to see an enlarged view

    Fig. Intake manifold gasket positioning-2004-2005 Eclipse 3.0L engine

  2.  
  3. Install the intake manifold. Coat the retaining bolts in clean engine oil. Torque the retaining bolts to specification.
  4.  
  5. Continue the installation in the reverse order of the removal procedure.
  6.  

  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect battery negative cable.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Accelerator cable
     
    Air intake hose
     
    Coolant hose from the throttle housing
     
    Vacuum lines, label for reference
     
    High pressure fuel line and fuel return hose
     
    Throttle control cable brackets
     

  8.  
  9. Disconnect the following:

    Engine Coolant Temperature (ECT) sensor and gauge sender
     
    Idle Air Control (IAC) motor
     
    Exhaust Gas Recirculation (EGR) temperature sensor
     
    Ignition coil
     
    Knock (KS) sensor
     
    Heated Oxygen (HO 2 S) sensor
     
    Throttle Position (TP) sensor
     
    Distributor (if equipped)
     
    Air conditioning temperature sensor
     
    Ignition power transistor
     
    Fuel injectors
     

  10.  
  11. Remove or disconnect the following:

    Spark plug wires
     
    Intake manifold stay bracket
     
    Intake manifold mounting bolts and remove the intake manifold assembly
     

  12.  

To install:

  1. Clean all gasket material from the cylinder head intake mounting surface and intake manifold assembly.
  2.  
  3. Install or connect the following:

    Intake manifold, using a new gasket. Torque the manifold in a crisscross pattern, starting from the inside and working outwards to 15 ft. lbs. (20 Nm).
     
    Fuel injectors, fuel rail and pressure regulator to the engine. Torque the retaining bolts to 48 inch lbs. (6 Nm).
     
    Intake manifold brace bracket and tighten bolts to 21 ft. lbs. (29 Nm)
     
    Spark plug wires
     

  4.  
  5. Connect the following:

    ECT sensor and gauge sender
     
    IAC motor
     
    EGR temperature sensor
     
    Ignition coil
     
    KS sensor
     
    HO 2 S sensor
     
    TP sensor
     
    Distributor (if equipped)
     
    Air conditioning temperature sensor
     
    Ignition power transistor
     
    Fuel injectors
     

  6.  
  7. Install or connect the following:

    Throttle control cable brackets
     
    High pressure fuel line and fuel return hose
     
    Vacuum lines
     
    Coolant hoses
     
    Accelerator cable
     
    Air intake hose
     

  8.  
  9. Fill the system with coolant.
  10.  
  11. Connect the negative battery cable.
  12.  

3.8L Engines
  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the air cleaner assembly.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove the intake manifold plenum assembly.
  10.  
  11. Disconnect the injector connector wiring assembly, high pressure hose connection, O-ring and fuel return hose.
  12.  
  13. Disconnect the vacuum hose connection. Remove the fuel rail, injector and fuel pressure regulator. Remove the harness bracket.
  14.  
  15. Remove the PCV hose connection. Remove the left timing belt front upper cover. Remove the right timing belt front upper cover. Remove the water pump bracket.
  16.  
  17. Remove the intake manifold retaining bolts. Remove the intake manifold from the engine. Discard the gaskets.

    Click image to see an enlarged view

    Fig. Intake manifold and related components-2004-2005 Galant 3.8L engine

  18.  

To install:

  1. Be sure to use a new intake manifold gasket. Position the gasket on the engine.
  2.  
  3. Install the intake manifold. Coat the retaining bolts in clean engine oil. Torque the retaining bolts to specification.
  4.  
  5. Continue the installation in the reverse order of the removal procedure.
  6.  

Evolution
  1. Relieve the fuel system pressure. Remove the engine under cover.
  2.  
  3. Disconnect the negative battery cable. Drain the cooling system.
  4.  
  5. Remove the air cleaner assembly. Remove the engine strut tower bar assembly.
  6.  
  7. Disconnect the accelerator cable connection, throttle position sensor connector, idle air control motor connector, vacuum hose connection and water hose connection.
  8.  
  9. Remove the throttle body retaining bolts. Remove the throttle body from its mounting. Discard the gasket.
  10.  
  11. Remove the front axle crossmember bars. Remove the engine front roll stopper bracket bolt. Remove the front suspension crossmember.
  12.  
  13. Remove the front roll stopper bracket. Remove the transaxle case front roll stopper bracket.
  14.  
  15. Remove the rear roll stopper rod bolt. Remove the transaxle case rear roll stopper bracket.
  16.  
  17. Remove the engine rear roll stopper rod bolt. Remove the engine rear roll stopper rod bracket. Remove the rear roll stopper rod.
  18.  
  19. Remove the front exhaust pipe. Remove the engine center cover.
  20.  
  21. Disconnect the ignition coil connector, heated oxygen sensor (front) connector, CPS connector and knock sensor connector.
  22.  
  23. Disconnect the fuel injector connector, EVAP purge solenoid connector and fuel pressure solenoid connector.
  24.  
  25. Disconnect the MAP pressure sensor connector, vacuum hoses, fuel return hose connection and the high pressure fuel hose connection.
  26.  
  27. Remove the fuel rail, fuel injector, and fuel pressure regulator assembly. Remove the engine oil and dipstick holder assembly.
  28.  
  29. Disconnect the brake booster vacuum hose connection and the EVAP purge hose connection and the knock sensor connector.
  30.  
  31. Remove the EVAP purge solenoid. Disconnect the vacuum hose, fuel pressure solenoid and PCV hose.
  32.  
  33. Remove the alternator. Remove the EGR vacuum regulator solenoid connector.
  34.  
  35. Remove the EGR vacuum regulator solenoid and vacuum pipe and hose assembly. Remove the intake manifold bracket. Remove the ERG valve and gasket. Disconnect the ground cable connection.
  36.  
  37. Remove the MAP pressure sensor, CPK sensor and alternator brace.
  38.  
  39. Remove the engine hanger and harness bracket.
  40.  
  41. Remove the intake manifold retaining bolts. Remove the intake manifold from the engine.

    Click image to see an enlarged view

    Fig. Intake manifold and related components-Evolution

  42.  

To install:

  1. Be sure to use a new intake manifold gasket. Position the gasket on the engine.
  2.  
  3. Install the intake manifold. Coat the retaining bolts in clean engine oil. Torque the retaining bolts to specification.
  4.  
  5. Continue the installation in the reverse order of the removal procedure.
  6.  

 
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