MITSUBISHI LANCER 2006 Repair Manual

15-1
GROUP 15
INTAKE AND
EXHAUST
CONTENTS
GENERAL INFORMATIO N . . . . . . . .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> . . 15-5
REMOVAL 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 . . . . . . . . . . . . . . . . . . . . . .15-10
REMOVAL AND INSTALLATION . . . . . . . . 15-10

GENERAL INFORMATION
INTAKE AND EXHAUST15-2
GENERAL INFORMATION
M1151000100402
The exhaust pipe is divided into three parts.
SERVICE SPECIFICATION
M1151000300428
ItemStandard valueLimit
Manifold distortion of the installation surface mm0.15 or less0.20
SPECIAL TOOL
M1151000600399
ToolNumberNameUse
MD998770Oxygen sensor wrenchRemoval and installation of
engine control oxygen sensor

AIR CLEANER
INTAKE AND EXHAUST15-3
AIR CLEANER
REMOVAL AND INSTALLATIONM1151002100486
CAUTION
Parts marked by * are made of recycled-paper mixed plastic material, so observe the following pre-
cautions.
•Avoid any shock or load to these parts when removing and installing them.
•When installing, securely set the air cleaner cover clamp to the air cleaner body.
NOTE: Parts marked by * are made of recycled-paper mixed plastic material. Dispose of according to state
and local laws.
AC303618
4.0 ± 1.0 N·m
4.0 ± 1.0 N·m
10*
9* 4
1* 5
11
12 ± 1 N·m 9.0 ± 1.0 N·m
9.0 ± 1.0 N·m
AB
12 ± 1 N·m
Clamp
8*
3*
<4G1>

AC303619
4.0 ± 1.0 N·m
4.0 ± 1.0 N·m10*
9* 4
1* 5
11
12 ± 1 N·m 9.0 ± 1.0 N·m
9.0 ± 1.0 N·m
AB
12 ± 1 N·m
Clamp
8*
3*
<4G6>
6
7
N
2
8.8 ± 1.0 N·m
Removal steps
1.Air cleaner intake duct
2.Air cleaner air flow sensor connector
<4G6>
3.Air cleaner assembly <4G1> or Air
cleaner and air cleaner air flow sensor
assembly <4G6>
4.Rocker cover breather hose
connection
5.Air cleaner to throttle body duct
6.Air cleaner air flow sensor <4G6>
7.Air cleaner air flow sensor gasket
<4G6>
8.Air cleaner cover
9.Air cleaner element
10.Air cleaner body assembly
11 .Air cleaner bracket
AIR CLEA NER
INTAKE AN D EXHAU ST15-4
Removal steps (Continued)

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-372).
•Engine Coolant Draining (Refer to GROUP 14 - On-vehi-
cle Service P.14-21).
•Strut Tower Bar Removal (Refer to GROUP 42 P.42-9).
•Throttle Body Assembly Re moval (Refer to GROUP 13A
P.13A-383).
•Fuel Delivery Pipe and Fuel Injector Assembly Removal
(Refer to GROUP 13A
P.13A-381).
Post-installation Operation
•Fuel Delivery Pipe and Fuel Injector Assembly Installation
(Refer to GROUP 13A
P.13A-381).
•Throttle Body Assembly Inst allation (Refer to GROUP
13A
P.13A-383).
•Strut Tower Bar Installati on (Refer to GROUP 42 P.42-9).
•Engine Coolant Supplying (Refer to GROUP 14 - On-vehi-
cle Service P.14-21).
•Accelerator Cable Adjustment (Refer to GROUP 17 -
On-vehicle Service
P.17-2).
•Fuel Leak Check
AC303642AB
15
36
5
4 12
10
7
1
2
11
9 13
14
21 ± 4 N·m
9.0 ± 1.0 N·m
9.0 ± 1.0 N·m
18 ± 2 N·m
18 ± 2 N·m 18 ± 2 N·m
5.0 ± 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 connection
8.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.13B-325).
•Engine Coolant Draining (Refer to GROUP 14 - On-vehi-cle Service P.14-21).
•Strut Tower Bar Removal (Refer to GROUP 42 P.42-9).
•Throttle Body Assembly Re moval (Refer to GROUP 13B
P.13B-335).
•Fuel Delivery Pipe and Fuel Injector Assembly Removal
(Refer to GROUP 13B
P.13B-333).
Post-installation Operation
•Fuel Delivery Pipe and Fuel Injector Assembly Installation
(Refer to GROUP 13B P.13B-333).
•Throttle Body Assembly Inst allation (Refer to GROUP
13B P.13B-335).
•Strut Tower Bar Installati on (Refer to GROUP 42 P.42-9).
•Engine Coolant Supplying (Refer to GROUP 14 - On-vehi-
cle Service P.14-21).
•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
20 ± 2 N·m
11
9
10
2
12
N14
13N
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 connection
4.Engine control detonation sensor
connector
5.Engine oil level gauge and guide
assembly
6.Engine oil filler O-ring
7.Emission vacuum hose connection
Removal steps (Continued)

EXHAUST MANIFOLD
INTAKE AND EXHAUST15-7
INSPECTION
M1151003100616
Check the following points; replace the part if a prob-
lem 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
AC30366250 ± 10 N·m
24 ± 4 N·m
35 ± 6 N·m 17 ± 2 N·m
30 ± 2 N·m
N
3
7 12
4
N
6
8
44 ± 5 N·m
AB
9
5N
30 ± 2 N·m
30 ± 2 N·m
30 ± 2 N·m
(Engine oil)
8.Battery wirin g ha rne s s clamp
9.Inlet manifold st ay
10.Inlet manifold
11.Inlet manifold gask et
12.Emission vacuu m hose & pipe and
emis
sion s o lenoid valve assembly
13.EGR v a lve
14.EGR v a lve gasket
Remo va l st ep s ( C o n t in u e d)

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-ring
6.Exhaust manifold cover
7.Exhaust manifold bracket
8.Exhaust manifold
9.Exhaust manifold gasket
EXHAUST MANIFOLD
INTAKE AND EXHAUST15-8
REMOVAL SERVICE POINT
<> ENGINE CONTROL OXYGEN SEN-
SOR (FRONT) REMOVAL
AC212566AC
MD998770
Engine control
oxygen sensor
(front)
Use spe c ia l tool oxyg en sen s or wrench (MD9987 70)
to remove t
he eng ine contro l oxygen sen s or (fro nt).
INSTALLA T ION SER VICE POINT
>>A<< ENGINE CONT ROL OXYGEN SEN-
SOR (FRONT) INSTALLA TION
AC212566AC
MD998770
Engine control
oxygen sensor
(front)
Use spe c ia l tool oxyg en sen s or wrench (MD9987 70)
to inst
all the eng ine contro l oxyge n sen s or (f ront).

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·m
35 ± 6 N·m14 ± 1 N·m
14 ± 1 N·m
49 ± 5 N·m 29 ± 3 N·m
29 ± 3 N·m
N
3
4
1 2
5
N
8 944 ± 5 N·m
AB
1049 ± 5 N·m
6
7
9.0 ± 2.0 N·m 49 ± 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 bracket
6.Starter cover
7.Starter cover bracket
8.Engine hanger
9.Exhaust manifold
10.Exhaust manifold gasket
Removal steps (Continued)

EXHAUST PIPE AND MAIN MUFFLER
INTAKE AND EXHAUST15-10
REMOVAL SERVICE POINT
<> ENGINE CONTROL OXYGEN SEN-
SOR (FRONT) REMOVAL
AC212566AC
MD998770
Engine control
oxygen sensor
(front)
Use spe c ia l tool oxyg en sen s or wrench (MD9987 70)
to remove t
he eng ine contro l oxygen sen s or (fro nt).
INSTALLA T ION SER VICE POINT
>>A<< ENGINE CONT ROL OXYGEN SEN-
SOR (FRONT) INSTALLA TION
AC212566AC
MD998770
Engine control
oxygen sensor
(front)
Use spe c ia l tool oxyg en sen s or wrench (MD9987 70)
to inst
all the eng ine contro l oxyge n sen s or (f ront).
INSPECTIONM1151 0034 0054 3
Chec k the fo llowing point s; rep l ace the p a rt if a p r ob-
lem is found.
Exhaust Manifold Check
1.Check f o r damage o r cracking of a n y p a rt.
2.Using a straight e dge an d a fee l er ga uge, check
fo r distortio n of th e cylin der he ad in st allation
surface.
St a ndard val ue: 0.15 mm or les s
Limit: 0.20 mm
EXHAUST PIPE AND MAI N MUFFLER
REMOVA L AND INST ALLA TION
M1151 0087 0096 9
AC303694AC
1
3
50 ± 10 N·m
2
7
N
N
45
8 4
N9
10
59 ± 10 N·m
45 ± 5 N·m
13 ± 2 N·m
45 ± 5 N·m
13 ± 2 N·m
10
<4G1>