Mitsubishi Outlander 2003-06

Intake Manifold

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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. Remove or disconnect the following:

    Battery negative cable and drain the cooling system
     
    Air cleaner assembly
     
    Throttle body
     
    Fuel rail assembly
     
    Exhaust Gas Recirculation (EGR) valve and gasket
     
    Capacitor connector
     
    Brake booster vacuum hose
     
    Capacitor
     
    Vacuum pipe
     
    Brake booster vacuum hose connection
     
    Evaporative emission (EVAP) canister vacuum hose
     
    Manifold Absolute Pressure (MAP) sensor
     
    Knock Sensor (KS) connector
     
    EVAP purge solenoid valve connector
     
    Harness clamp
     
    KS connector clamp
     
    Oil dipstick guide and O-ring
     
    Harness clamp
     
    Lower radiator hose. Matchmark the clamp to the hose before removal.
     
    Heater hose
     
    Engine Coolant Temperature (ECT) gauge unit connector
     
    Thermostat housing and O-ring
     
    KS harness clamp
     
    MAP sensor and harness clamp
     
    Intake manifold stay
     
    Intake manifold stay
     
    Intake manifold bolt and manifold.
     
    Intake manifold gasket and discard
     

  6.  


    Click image to see an enlarged view

    Fig. Exploded view of the intake manifold and related components


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 as follows:
    1. Bolts: 16-20 ft. lbs. (21-27 Nm)
    2.  
    3. Nuts: 14-16 ft. lbs. (18-22 Nm)
    4.  

  4.  
  5. Install or connect the following:

    Intake manifold stay. Torque the bolt to 21-25 ft. lbs. (29-33 Nm)
     
    MAP sensor and harness clamp
     
    KS harness clamp
     
    Thermostat housing and O-ring. Clean the gasket mating surfaces, then apply a 3mm bead of 3M(TM) ADD part No. 8672, 3M(TM) ADD part No. 8679/8678 or equivalent.
     
    ECT gauge unit connector
     
    Heater hose
     
    Lower radiator hose. Matchmark the clamp to the hose before removal.
     
    Harness clamp
     
    Oil dipstick guide and O-ring
     
    KS connector clamp
     
    Harness clamp
     
    EVAP purge solenoid valve connector
     
    KS connector
     
    MAP sensor
     
    EVAP canister vacuum hose
     
    Brake booster vacuum hose connection
     
    Vacuum pipe
     
    Capacitor
     
    Brake booster vacuum hose
     
    Capacitor connector
     
    EGR valve and gasket
     
    Fuel rail assembly
     
    Throttle body
     
    Air cleaner assembly
     

  6.  
  7. Fill the system with coolant.
  8.  
  9. Connect the negative battery cable.
  10.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Battery negative cable and drain the cooling system
     
    Air cleaner assembly
     
    Throttle body
     
    Fuel rail assembly
     
    Exhaust Gas Recirculation (EGR) valve and gasket
     
    Capacitor connector
     
    Brake booster vacuum hose
     
    Capacitor
     
    Vacuum pipe
     
    Brake booster vacuum hose connection
     
    Evaporative emission (EVAP) canister vacuum hose
     
    Manifold Absolute Pressure (MAP) sensor
     
    Knock Sensor (KS) connector
     
    EVAP purge solenoid valve connector
     
    Harness clamp
     
    KS connector clamp
     
    Oil dipstick guide and O-ring
     
    Harness clamp
     
    Lower radiator hose. Matchmark the clamp to the hose before removal.
     
    Heater hose
     
    Engine Coolant Temperature (ECT) gauge unit connector
     
    Thermostat housing and O-ring
     
    KS harness clamp
     
    MAP sensor and harness clamp
     
    Intake manifold stay
     
    Intake manifold stay
     
    Intake manifold bolt and manifold.
     
    Intake manifold gasket and discard

    Click image to see an enlarged view

    Fig. Intake manifold and related components

     

  6.  

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 specification.
  4.  
  5. Install or connect the following:

    Intake manifold stay. Torque the bolt to 21-25 ft. lbs. (29-33 Nm)
     
    MAP sensor and harness clamp
     
    KS harness clamp
     
    Thermostat housing and O-ring. Clean the gasket mating surfaces, then apply a 3mm bead of 3M( ADD part No. 8672, 3M( ADD part No. 8679/8678 or equivalent.
     
    ECT gauge unit connector
     
    Heater hose
     
    Lower radiator hose. Matchmark the clamp to the hose before removal.
     
    Harness clamp
     
    Oil dipstick guide and O-ring
     
    KS connector clamp
     
    Harness clamp
     
    EVAP purge solenoid valve connector
     
    KS connector
     
    MAP sensor
     
    EVAP canister vacuum hose
     
    Brake booster vacuum hose connection
     
    Vacuum pipe
     
    Capacitor
     
    Brake booster vacuum hose
     
    Capacitor connector
     
    EGR valve and gasket
     
    Fuel rail assembly
     
    Throttle body
     
    Air cleaner assembly
     

  6.  
  7. Fill the system with coolant.
  8.  
  9. Connect the negative battery cable.
  10.  

 
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