intake manifold removal MITSUBISHI LANCER 2005 Workshop Manual

15-1
GROUP 15
INTAKE AND
EXHAUST
CONTENTS
GENERAL INFORMATION . . . . . . . .15-2
SERVICE SPECIFICATION . . . . . . . .15-2
SPECIAL TOOL . . . . . . . . . . . . . . . . .15-2
AIR CLEANER . . . . . . . . . . . . . . . . . .15-3
REMOVAL AND INSTALLATION . . . . . . . . 15-3
INLET MANIFOLD . . . . . . . . . . . . . . .15-5
REMOVAL AND INSTALLATION <4G1> . . 15-5REMOVAL AND INSTALLATION <4G6> . . 15-6
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 15-7
EXHAUST MANIFOLD . . . . . . . . . . . .15-7
REMOVAL AND INSTALLATION <4G1> . . 15-7
REMOVAL AND INSTALLATION <4G6> . . 15-9
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 15-10
EXHAUST PIPE AND MAIN
MUFFLER . . . . . . . . . . . . . . . . . . . . . .15-11
REMOVAL AND INSTALLATION . . . . . . . . 15-11

GENERAL INFORMATION
INTAKE AND EXHAUST15-2
GENERAL INFORMATION
M1151000100402The exhaust pipe is divided into three parts.
SERVICE SPECIFICATION
M1151000300428
SPECIAL TOOL
M1151000600399
Item Standard value Limit
Manifold distortion of the installation surface mm 0.15 or less 0.20
Tool Number Name Use
MD998770 Oxygen sensor wrench Removal and installation of
engine control oxygen sensor

INLET MANIFOLD
INTAKE AND EXHAUST15-5
INLET MANIFOLD
REMOVAL AND INSTALLATION <4G1>M1151003000749
Pre-removal Operation
•Fuel Line Pressure Reduction (Refer to GROUP 13A -
On-vehicle Service P.13A-389).
•Engine Coolant Draining (Refer to GROUP 14 -
On-vehicle Service P.14-22).
•Strut Tower Bar Removal (Refer to GROUP 42 P.42-9).
•Throttle Body Assembly Removal (Refer to GROUP 13A
P.13A-400).
•Fuel Delivery Pipe and Fuel Injector Assembly Removal
(Refer to GROUP 13A P.13A-398).Post-installation Operation
•Fuel Delivery Pipe and Fuel Injector Assembly Installation
(Refer to GROUP 13A P.13A-398).
•Throttle Body Assembly Installation (Refer to GROUP
13A P.13A-400).
•Strut Tower Bar Installation (Refer to GROUP 42 P.42-9).
•Engine Coolant Supplying (Refer to GROUP 14 -
On-vehicle Service P.14-22).
•Accelerator Cable Adjustment (Refer to GROUP 17 -
On-vehicle Service P.17-2).
•Fuel Leak Check
AC303642AB
15
3
6
5
412 10 71
2
11
913
14
21 ± 4 N·m
9.0 ± 1.0 N·m
9.0 ± 1.0 N·m
18 ± 2 N·m
18 ± 2 N·m18 ± 2 N·m5.0 ± 1.0 N·m
31 ± 3 N·m
49 ± 9 N·m
N
N
N
8
Removal steps
1. Inlet manifold absolute pressure
sensor
2. Engine control pressure sensor
O-ring
3. Engine control detonation sensor
connector
4. T/M housing front lower cover stay
(L.H.)
5. Battery wiring harness clamp
connection
6. Inlet manifold stay
7. Brake booster vacuum hose
connection8. Emission control equip hose
connection
9. Fuel vapour control hose
connection
10. Inlet manifold stay
11. Inlet manifold
12. Inlet manifold gasket
13. EGR valve
14. EGR valve gasket
15. Emission vacuum hose & pipe and
emission solenoid valve assembly Removal steps (Continued)

INLET MANIFOLD
INTAKE AND EXHAUST15-6
REMOVAL AND INSTALLATION <4G6>M1151003001236
Pre-removal Operation
•Fuel Line Pressure Reduction (Refer to GROUP 13A -
On-vehicle Service P.13A-389).
•Engine Coolant Draining (Refer to GROUP 14 -
On-vehicle Service P.14-22).
•Strut Tower Bar Removal (Refer to GROUP 42 P.42-9).
•Throttle Body Assembly Removal (Refer to GROUP 13B
P.13B-336).
•Fuel Delivery Pipe and Fuel Injector Assembly Removal
(Refer to GROUP 13B P.13B-334).Post-installation Operation
•Fuel Delivery Pipe and Fuel Injector Assembly Installation
(Refer to GROUP 13B P.13B-334).
•Throttle Body Assembly Installation (Refer to GROUP
13B P.13B-336).
•Strut Tower Bar Installation (Refer to GROUP 42 P.42-9).
•Engine Coolant Supplying (Refer to GROUP 14 -
On-vehicle Service P.14-22).
•Accelerator Cable Adjustment (Refer to GROUP 17 -
On-vehicle Service P.17-2).
•Fuel Leak Check
AC303657
9.0 ± 1.0 N·m11 ± 1 N·m
20 ± 2 N·m
31 ± 3 N·m 36 ± 6 N·m
20 ± 2 N·m
20 ± 2 N·m
36 ± 6 N·m
36 ± 6 N·m
11
9 10 212
N1413N
AB
5.0 ± 1.0 N·m
3
1
11 ± 1 N·m
4
N
13 ± 1 N·m
5
6
(Engine oil)
7
8
Removal steps
1. Emission control equip hose
connector
2. Brake booster vacuum hose
connection
3. Earth cable connection4. Engine control detonation sensor
connector
5. Engine oil level gauge and guide
assembly
6. Engine oil filler O-ring
7. Emission vacuum hose connectionRemoval steps (Continued)

EXHAUST MANIFOLD
INTAKE AND EXHAUST15-7
INSPECTIONM1151003100616
Check the following points; replace the part if a
problem is found.
Inlet Manifold Check
1. Check for damage or cracking of any part.2. Clogging of the negative pressure (vacuum) outlet
port, or clogging of the exhaust gas recirculation
passages.
3. Using a straight edge and feeler gauge, check for
distortion of the cylinder head installation surface.
Standard value: 0.15 mm or less
Limit: 0.20 mm
EXHAUST MANIFOLD
REMOVAL AND INSTALLATION <4G1>M1151003300568
8. Battery wiring harness clamp
9. Inlet manifold stay
10. Inlet manifold
11. Inlet manifold gasket
12. Emission vacuum hose & pipe and
emission solenoid valve assembly
13. EGR valve
14. EGR valve gasketRemoval steps (Continued)
AC30366250 ± 10 N·m 24 ± 4 N·m
35 ± 6 N·m17 ± 2 N·m 29 ± 3 N·m
N
3
7
12 4
N
6
8
44 ± 5 N·m
AB
9
5N
29 ± 3 N·m
29 ± 3 N·m
29 ± 3 N·m
(Engine oil)

EXHAUST MANIFOLD
INTAKE AND EXHAUST15-8
REMOVAL SERVICE POINT
<> ENGINE CONTROL OXYGEN
SENSOR (FRONT) REMOVAL
Use special tool oxygen sensor wrench (MD998770)
to remove the engine control oxygen sensor (front).
INSTALLATION SERVICE POINT
>>A<< ENGINE CONTROL OXYGEN
SENSOR (FRONT) INSTALLATION
Use special tool oxygen sensor wrench (MD998770)
to install the engine control oxygen sensor (front).
Removal steps
1. Front exhaust pipe connection
2. Exhaust pipe gasket
<> >>A<<3. Engine control oxygen sensor (front)
4. Engine oil level gauge and guide
assembly
5. Engine oil filler O-ring6. Exhaust manifold cover
7. Exhaust manifold bracket
8. Exhaust manifold
9. Exhaust manifold gasketRemoval steps (Continued)
AC212566AC
MD998770
Engine control
oxygen sensor
(front)
AC212566AC
MD998770
Engine control
oxygen sensor
(front)

EXHAUST MANIFOLD
INTAKE AND EXHAUST15-9
REMOVAL AND INSTALLATION <4G6>M1151003300579
Pre-removal and Post-installation Operation
Under cover Removal and Installation
AC30368050 ± 10 N·m 44 ± 5 N·m35 ± 6 N·m14 ± 1 N·m
14 ± 1 N·m
49 ± 5 N·m29 ± 3 N·m
29 ± 3 N·m
N
3
4
12 5
N
8944 ± 5 N·m
AB
1049 ± 5 N·m
6 7
9.0 ± 2.0 N·m49 ± 9 N·m
Removal steps
1. Front exhaust pipe connection
2. Exhaust pipe gasket
<> >>A<<3. Engine control oxygen sensor (front)
4. Exhaust manifold cover
5. Exhaust manifold bracket6. Starter cover
7. Starter cover bracket
8. Engine hanger
9. Exhaust manifold
10. Exhaust manifold gasketRemoval steps (Continued)

EXHAUST MANIFOLD
INTAKE AND EXHAUST15-10
REMOVAL SERVICE POINT
<> ENGINE CONTROL OXYGEN
SENSOR (FRONT) REMOVAL
Use special tool oxygen sensor wrench (MD998770)
to remove the engine control oxygen sensor (front).
INSTALLATION SERVICE POINT
>>A<< ENGINE CONTROL OXYGEN
SENSOR (FRONT) INSTALLATION
Use special tool oxygen sensor wrench (MD998770)
to install the engine control oxygen sensor (front).
INSPECTIONM1151003400543
Check the following points; replace the part if a
problem is found.
Exhaust Manifold Check
1. Check for damage or cracking of any part.2. Using a straight edge and a feeler gauge, check
for distortion of the cylinder head installation
surface.
Standard value: 0.15 mm or less
Limit: 0.20 mm
AC212566AC
MD998770
Engine control
oxygen sensor
(front)
AC212566AC
MD998770
Engine control
oxygen sensor
(front)

IGNITION SYSTEM
ENGINE ELECTRICAL16-43
DETONATION SENSOR
REMOVAL AND INSTALLATIONM1163002800556
CAUTION
Do not drop or hit the detonation sensor against other components. Internal damage may result, and
the detonation sensor will need to be replaced.
AC303971
21
23 ± 2 N·m
AB
<4G1>Cylinder block
(Intake side)
AC303972
21
23 ± 2 N·mAB
<4G6>Inlet manifold
Removal steps
1. Engine control detonation sensor
connector
<> >>A<<2. Engine control detonation sensor