Mitsubishi Montero, Sport 1998-06

Exhaust Manifold

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Removal & Installation



2.4L Engine
  1. Remove or disconnect the following:
    CAUTION
    Wait at least 90 seconds after the negative battery cable is disconnected to prevent possible deployment of the air bag.



    Negative battery cable
     



    Heat cowl from the exhaust manifold
     
    Aspirator valve assembly, if equipped
     
    Oil dipstick and guide
     
    Oxygen (O 2 S) sensor connector and ground cable, if equipped
     
    Exhaust pipe from the manifold
     
    Exhaust manifold and gasket from the engine
     

  2.  

To install:

  1. Install or connect the following:

    Exhaust manifold. Torque the M8 mounting nuts to 22 ft. lbs. (29 Nm) and the M10 mounting bolts 36 ft. lbs. (49 Nm). starting from the middle and working outward.
     
    O 2 S sensor connector and ground cable, if equipped
     
    Exhaust pipe to the manifold. Torque the nuts to 35ft. (49 Nm).
     
    Aspirator valve assembly, if removed
     
    Heat cowl to the exhaust manifold. Torque the bolts to 117 inch lbs. (13 Nm).
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for exhaust leaks.
  4.  

3.0L & 3.5L Engines
  1. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust pipe from the exhaust manifolds
     
    Oil dipstick, guide and O-ring
     
    Heat shields
     
    Exhaust manifolds
     

  2.  
  3. Clean the gasket mounting surfaces. Inspect the manifolds for cracks, flatness and/or damage.
  4.  

To install:

  1. Install or connect the following:

    New gasket and exhaust manifold. Torque the nuts to 33 ft. lbs. (44 Nm) on 3.0L engines and 22 ft. lbs. (29 Nm) on 3.5L engines.
     
    Heat shield, Torque the bolts to 10 ft. lbs. (14 Nm).
     
    Exhaust pipe to the exhaust manifolds. Torque the nuts to 35ft. (49 Nm).
     
    Oil dipstick, guide and new O-ring
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for exhaust leaks.
  4.  

3.0L Engine
12-Valve

To remove the right exhaust manifold, start by removing the front exhaust pipe.

  1. Remove or disconnect the following:

    Air duct
     
    Heat protector
     
    Engine hanger
     
    Generator stay
     
    Exhaust manifold
     
    Exhaust manifold gasket
     

  2.  

To remove the left exhaust manifold, start by removing the front exhaust pipe.

  1. Remove or disconnect the following:

    Heat protector
     
    Air intake plenum stay (front)
     
    Bracket
     
    Exhaust manifold
     
    Exhaust manifold gasket

    Click image to see an enlarged view

    Fig. Removing and installing exhaust manifold 3.0L 12V (1996)

     

  2.  

To install:



Click image to see an enlarged view

Fig. Installing exhaust manifold gasket

To install, reverse removal procedure.

24-Valve

To remove the right exhaust manifold; start by removing the front exhaust pipe (Federal) or the warm up Three-Way catalytic converter (California) and the air duct and air cleaner cover.

  1. Remove or disconnect the following:

    Heat protector (RH)
     
    Exhaust manifold (RH)
     
    Gasket
     

  2.  

To remove the left exhaust manifold; start by removing the front exhaust pipe (Federal) or the warm up Three-Way catalytic converter (California) and the battery and battery tray.

  1. Remove or disconnect the following:

    Heat protector (LH)
     
    EGR pipe
     
    Gasket
     
    Exhaust manifold (LH)
     
    Gasket

    Click image to see an enlarged view

    Fig. Removing and installing exhaust manifold 3.0L 24V (1996)

     

  2.  

To install:

To install the exhaust manifold, reverse the removal procedure.

3.8L Engine
  1. Remove or disconnect the following:

    Negative battery cable
     
    Front exhaust pipe from the exhaust manifolds
     
    Air cleaner assembly
     
    Battery and battery tray
     
    Exhaust Gas Recirculation (EGR) pipe and gasket
     
    Right side heat shield
     
    Right side exhaust manifold and gasket
     
    Oil dipstick, guide and O-ring
     
    Transmission fluid dipstick guide
     
    Left side heat shield
     
    Left side exhaust manifold and gasket
     

  2.  
  3. Clean the gasket mounting surfaces. Inspect the manifolds for cracks, flatness and/or damage.
  4.  

To install:

  1. Install or connect the following:

    New gasket and left side exhaust manifold. Torque the nuts to 30-36 ft. lbs. (39-49 Nm).
     
    Left side heat shield
     
    Transmission fluid dipstick guide
     
    Oil dipstick, guide and O-ring
     
    New gasket and right side exhaust manifold. Torque the nuts to 30-36 ft. lbs. (39-49 Nm).
     
    Right side heat shield
     
    EGR gasket and pipe
     
    Battery tray and battery
     
    Air cleaner assembly
     
    Front exhaust pipe to the exhaust manifolds. Torque the nuts to 35ft. (49 Nm).
     
    Oil dipstick, guide and new O-ring
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for exhaust leaks.
  4.  


    Click image to see an enlarged view

    Fig. Exploded view of the exhaust manifolds-3.8L engine


  1. Remove or disconnect the following:

    Negative battery cable
     
    Front exhaust pipe from the exhaust manifolds
     
    Air cleaner assembly
     
    Battery and battery tray
     
    Exhaust Gas Recirculation (EGR) pipe and gasket
     
    Right side heat shield
     
    Right side exhaust manifold and gasket
     
    Oil dipstick, guide and O-ring
     
    Transmission fluid dipstick guide
     
    Left side heat shield
     
    Left side exhaust manifold and gasket
     

  2.  
  3. Clean the gasket mounting surfaces. Inspect the manifolds for cracks, flatness and/or damage.
  4.  

To install:

  1. Install or connect the following:

    New gasket and left side exhaust manifold. Torque the nuts to 30-36 ft. lbs. (39-49 Nm).
     
    Left side heat shield
     
    Transmission fluid dipstick guide
     
    Oil dipstick, guide and O-ring
     
    New gasket and right side exhaust manifold. Torque the nuts to 30-36 ft. lbs. (39-49 Nm).
     
    Right side heat shield
     
    EGR gasket and pipe
     
    Battery tray and battery
     
    Air cleaner assembly
     
    Front exhaust pipe to the exhaust manifolds. Torque the nuts to 35ft. (49 Nm).
     
    Oil dipstick, guide and new O-ring
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for exhaust leaks.

    Click image to see an enlarged view

    Fig. Exhaust manifolds and related components-3.8L engine

  4.  

 
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