Mitsubishi Pajero Pinin. Manual - part 141

INTAKE AND EXHAUST – 

General/Service Specification/Air Cleaner

15-1

GROUP 15

INTAKE AND EXHAUST

GENERAL

OUTLINE OF CHANGES

The following service procedures have been established due to the addition of vehicle with 4G9-MPI engine.
Other contents are the same as 4G9-GDI engine.

SERVICE SPECIFICATION

Items

Standard value

Limit

Distortion of the intake manifold installation surface mm

0.15 or less

0.20

AIR CLEANER

REMOVAL AND INSTALLATION

<4G9-MPI>

1

3

4

5

6

7

9

2

8

10

4.0 

±

1.0

  N

·

m

12 

±

2

  N

·

m

3.9 

±

1.0

  N

·

m

9.0 

±

1.0

  N

·

m

8.8 

±

1.0

  N

·

m

3.9 

±

1.0

  N

·

m

11

12

13

Removal steps

1. Air intake hose and resonator
2. Air intake hose
3. Resonator
4. Air flow sensor connector
5. Air flow sensor and air cleaner cover
6. Air flow sensor
7. Air cleaner cover

8. Air cleaner element
9. Air duct

10. Air cleaner

11. Breather hose connection

12. Air intake pipe
13. Air hose

INTAKE AND EXHAUST – 

Intake Manifold

15-2

INTAKE MANIFOLD

REMOVAL AND INSTALLATION

<4G9-MPI>

Pre-removal and Post-installation Operation

D

Engine Coolant Draining and Supplying

D

Under Cover Removal and Installation

D

Air Cleaner Removal and Installation
(Refer to P.15-2.)

D

Throttle Body and Throttle Cable Bracket Removal
and Installation 
(Refer to GROUP 13C.)

6

11

8

1

2

4

5

3

O-ring

Delivery pipe

7

Engine oil

10

9

22

10

12

21

23

19

17

16

14

13

15

18

7

20

9.0 

±

1.0

  N

·

m

12 

±

1

  N

·

m

22 

±

4

  N

·

m

9.0 

±

1.0

  N

·

m

5.0 

±

1.0

  N

·

m

5.0 

±

1.0

  N

·

m

31 

±

3

  N

·

m

20 

±

2

  N

·

m

20 

±

2

  N

·

m

24 

±

1

  N

·

m

24

Removal steps

1. Noise condenser connector
2. Purge control solenoid valve 

connector

3. EGR solenoid valve connector
4. Crank angle sensor connector
5. Detonation sensor connector
6. Injector connector
7. Control harness clamp
8. Intake manifold vacuum hose 

connection

9. Brake booster vacuum hose 

connection

"

A

A

10. Fuel pressure hose

11. Return hose

A

B

"

12. Delivery pipe, injector and fuel 

pressure regulator assembly

13. PCV hose connection
14. Vacuum hose connection
15. Solenoid valve and bracket assembly
16. Radiator upper hose
17. Water outlet fitting
18. Battery harness clamp
19. A/T oil cooler pipe clamp <A/T>
20. Earth cable connection
21. Intake manifold stay
22. Intake manifold assembly
23. Intake manifold gasket
24. EGR valve

INTAKE AND EXHAUST – 

Intake Manifold

15-3

REMOVAL SERVICE POINT

A

A

"

FUEL PUMP PROTECTOR REMOVAL

Lift up the transmission with a jack to create clearance between
the engine and the front deck, and remove the fuel pump
protector.

A

B

"

DELIVERY PIPE, INJECTOR AND FUEL
PRESSURE REGULATOR ASSEMBLY REMOVAL

Remove the delivery pipe (with the injectors and fuel pressure
regulator attached to it).

Caution
Care must be taken, when removing the delivery pipe,
not to drop the injector.

INSTALLATION SERVICE POINT

"

A

A

HIGH-PRESSURE FUEL HOSE INSTALLATION

1.

When connecting the high-pressure fuel hose to the
delivery pipe, apply a small amount of new engine oil
to the O-ring and then insert the high-pressure fuel hose,
being careful not to damage the O-ring.

Caution
Be careful not to let any engine oil get into the delivery
pipe.

2.

While turning the high-pressure fuel hose to the left and
right, install it to the delivery pipe.

3.

Check to be sure that the high-pressure fuel hose turns
smoothly.
If it does not turn smoothly, the O-ring may be trapped,
remove the high-pressure fuel hose and then re-insert
it into the delivery pipe and check once again.

INSPECTION

Check the following points; replace the part if a problem is
found.

INTAKE MANIFOLD CHECK

1.

Check for damage or cracking of any part.

2.

Check for obstruction of the negative pressure (vacuum)
outlet port, and for obstruction of the water passage or
gas passage.

3.

Using a straight edge and thickness gauge, check for
distortion of the cylinder head installation surface.

Standard value: 0.15 mm or less

Limit: 0.20 mm

High-pressure fuel hose

O-ring

Delivery pipe

INTAKE AND EXHAUST – 

Exhaust Manifold

15-4

EXHAUST MANIFOLD

REMOVAL AND INSTALLATION

<4G9-MPI>

Pre-removal and Post-installation Operation

D

Under Cover Removal and Installation

D

Air Cleaner Removal and Installation
(Refer to P.15-2.)

D

Power Steering Oil Pump Bracket Removal and
Installation

1

2

4

5

3

7

6

13 

±

1

  N

·

m

29 

±

3

  N

·

m

13 

±

1

  N

·

m

35 

±

5

  N

·

m

35 

±

5

  N

·

m

35 

±

6

  N

·

m

14 

±

1

  N

·

m

29 

±

3

  N

·

m

18 

±

2

  N

·

m

Removal steps

1. Front exhaust pipe connection
2. Exhaust manifold bracket
3. Engine oil level gauge guide
4. Washer tank filler tube

5. Exhaust manifold cover
6. Exhaust manifold
7. Exhaust manifold gasket