Mitsubishi Colt Ralliart. Manual - part 113

INTERCOOLER

INTAKE AND EXHAUST

15-8

INTERCOOLER

REMOVAL AND INSTALLATION <4G1>

M1151004200188

AC600078

6.0 ± 1.0 N·m

1

2

3

4

5

6

7

8

9

10

20

13

14

15

N

17

19

16

18

11

6.0 ± 1.0 N·m

24 ± 4 N·m

6.0 ± 1.0 N·m

6.0 ± 1.0 N·m

10 ± 1 N·m

5.0 ± 1.0 N·m

N

20 ± 4 N·m

6.0 ± 1.0 N·m

6.0 ± 1.0 N·m

6.0 ± 1.0 N·m

11 ± 2 N·m

11 ± 2 N·m

AB

12

6.0 ± 1.0 N·m

11 ± 2 N·m

5.4 ± 1.0 N·m

5.4 ± 1.0 N·m

5.4 ± 1.0 N·m

5.4 ± 1.0 N·m

7.5 ± 1.0 N·m

6.0 ± 1.0 N·m

Removal steps 

>>

H

<<

1.

Air hose C

>>

G

<< 2.

Air by-pass hose

>>

F

<<

3.

Air by-pass valve

•

Air cleaner assembly (Refer to 

P.15-6

)

>>

E

<<

4.

Air pipe B

>>

D

<<

5.

Air hose D

Removal steps (Continued)

Main

Index

Group

TOC

INTERCOOLER

INTAKE AND EXHAUST

15-9

INSTALLATION SERVICE POINTS
>>A<<AIR HOSE A INSTALLATION

AC402293

Intercooler assembly
(inlet side)  

Mating mark (green)

Air hose A

Mating mark

AC402293AG

1. Install by aligning the mating mark (green) on air 

hose A and the mating mark on the intercooler 
assembly (inlet side).

AC402297

AB

Air outlet fitting

Mating mark
   (yellow)

Air hose A

2. Install by aligning the mating marks (yellow) on air 

hose A and on the air outlet fitting.

>>B<<AIR HOSE B INSTALLATION

AC402295

Air hose B

Mating mark

Mating mark
(yellow)

Intercooler
air pipe

AC402295AC

Install by aligning the mating mark (yellow) on air 
hose B and the mating mark on the intercooler air 
pipe.

>>C<<AIR PIPE A INSTALLATION

AC600076AB

Mating mark 
(white)

Air pipe A

Air hose B

Install by aligning the mating marks (white) on air 
pipe A and on air hose B.

>>D<<AIR HOSE D INSTALLATION

AC600077AB

Throttle body

Air hose D

Mating mark 
(white)

Projection

Install by aligning the mating mark (white) on air 
hose D and the projection on the throttle body.

>>

C

<<

6.

Air pipe A

7.

Bracket

>>

B

<<

8.

Air hose B

>>

A

<<

9.

Air hose A

10. Air outlet fitting
11. Gasket
•

Front bumper assembly (Refer to 
GROUP 51 

− Front Bumper 

Assembly, Radiator Grille 

P.51-2

).

•

Side under cover (LH)

12. Intercooler assembly, intercooler 

inlet air duct, intercooler air pipe

13. Intercooler assembly
14. Intercooler air pipe
15. O-ring
16. Intercooler inlet air duct
17. Bracket
18. Bracket
19. Intercooler baffle plate
20. Bracket

Removal steps (Continued)

Main

Index

Group

TOC

INTERCOOLER

INTAKE AND EXHAUST

15-10

>>E<<AIR PIPE B INSTALLATION

AC402294

    4 mm
(yellow line)

Air hose D

Mating mark 
    (yellow)

Air pipe B

AC402294AB

1. Align the end of air hose D so that the width of the 

yellow line on air pipe B should be 4 mm.

2. Install by aligning the mating marks (yellow) on air 

pipe B and on air hose D.

>>F<<AIR BY-PASS VALVE 
INSTALLATION

AC600112AB

Air by-pass valve

Engine
air intake hose

Mating mark
(white)

Mating mark

Install by aligning the mating mark (white) on the air 
by-pass valve and the mating mark on the engine air 
intake hose.

>>G<<AIR BY-PASS HOSE 
INSTALLATION

AC402296

AH

Air pipe B

Air by-pass hose

Mating mark
(green)

Mating mark

1. Install by aligning the mating mark (green) on the 

air by-pass hose and the mating mark on air pipe 
B.

AC402291

Rib

Air by-pass hose

Air by-pass valve

Mating mark (white) 

AC402291AB

2. Install by aligning the mating mark (white) on the 

air by-pass hose and the centre of the air by-pass 
valve rib.

>>H<<AIR HOSE C INSTALLATION

AC402296

AG

Air pipe B

Mating mark 
(yellow)

Air hose C

1. Install by aligning the mating marks (yellow) on air 

hose C and on air pipe B.

AC402292

AE

Mating mark
(white)

Air pipe A

Mating mark
(green)

Air hose C

2. Install by aligning the mating mark (green) on the 

air hose C and the mating mark (white) on the air 
pipe A.

Main

Index

Group

TOC

INLET MANIFOLD

INTAKE AND EXHAUST

15-11

INLET MANIFOLD

REMOVAL AND INSTALLTION <4A9>

M1151003001816

Pre-removal Operation
• Engine Coolant Draining (Refer to GROUP 14, On-vehicle 

Service 

− Engine Coolant Replacement 

P.14-4

).

• Air Cleaner Assembly, Air Intake Duct Removal (Refer to 

P.15-5

).

• Throttle Body Removal (Refer to GROUP 13A, Throttle 

Body 

P.13A-370

).

• Fuel Injector Removal (Refer to Group 13A, Injector 

P.13A-367

).

• EGR Valve Assembly Removal <CVT> (Refer to GROUP 

17, EGR Valve 

P.17-22

).

Post-installation Operation
• EGR Valve Assembly Installation <CVT> (Refer to 

GROUP 17, EGR Valve 

P.17-22

).

• Fuel Injector Installation (Refer to GROUP 13A, Injector 

P.13A-367

).

• Throttle Body Installation (Refer to GROUP 13A, Throttle 

Body 

P.13A-370

).

• Air Cleaner Assembly, Air Intake Duct Installation (Refer 

to 

P.15-5

).

• Engine Coolant Refilling (Refer to GROUP 14, On-vehicle 

Service 

− Engine Coolant Replacement 

P.14-4

).

AC601295AB

14 ± 3 N·m

N

14

1

2

3

4

5

6

7

8

12

13

6.0 ± 0.5 N·m

18 ± 1 N·m

18 ± 1 N·m

9

11 ± 1 N·m

15

10

11

Removal steps 

1.

Harness clamp connection

2.

Alternator connector

3.

Alternator terminal

4.

PCV hose connection

5.

Brake booster vacuum hose 
connection <M/T>

6.

Purge hose connection <M/T>

7.

Manifold absolute pressure sensor 
connector

>>

A

<<

8.

Screw

9.

Manifold absolute pressure sensor

10. Harness clamp connection
11. Harness clamp connection <M/T>
12. Inlet manifold stay <M/T>
13. Inlet manifold
14. Inlet manifold gasket
15. Ball stud

Removal steps (Continued)

Main

Index

Group

TOC