Mitsubishi Galant (2004+). Manual - part 1659

 

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Mitsubishi Galant (2004+). Manual - part 1659

 

 

INTAKE MANIFOLD PLENUM

TSB Revision

INTAKE AND EXHAUST

15-7

Required Special Tool:

• MD998412: Guide

INSTALLATION SERVICE POINT

.

>>A<< INTAKE MANIFOLD PLENUM INSTALLATION
Use special tool MD998412 to install the intake manifold ple-
num.

REMOVAL STEPS

1.

MANIFOLD ABSOLUTE 
PRESSURE SENSOR 
CONNECTOR

2.

CONTROL WIRING HARNESS 
AND INJECTOR WIRING 
HARNESS COMBINATION 
CONNECTOR

3.

CRANKSHAFT POSITION 
SENSOR CONNECTOR

4.

KNOCK SENSOR CONNECTOR

5.

POWER STEERING PRESSURE 
SWITCH CONNECTOR

6.

EVAPORATIVE EMISSION 
PURGE SOLENOID CONNECTOR

7.

EXHAUST GAS RECIRCULATION 
VALVE CONNECTOR

8.

VACUUM HOSE CONNECTION

9.

PURGE HOSE CONNECTION

10. POWER STEERING PRESSURE 

HOSE CLAMP

11. POWER STEERING PRESSURE 

HOSE CLAMP BRACKET

12. INTAKE MANIFOLD PLENUM 

STAY, REAR

STEERING GEAR AND LINKAGE 
PROTECTOR (REFER TO 37A, 
STEERING GEAR BOX AND 
LINKAGE 

P.37A-34

)

13. EGR PIPE
14. EGR PIPE GASKET

POWER STEERING OIL PUMP 
(REFER TO 37A, POWER 
STEERING OIL PUMP ASSEMBLY 

P.37A-55

)

15. POWER STEERING OIL PUMP 

BRACKET CONNECTING BOLT

16. INTAKE MANIFOLD PLENUM 

STAY, FRONT

>>A<<

17. INTAKE MANIFOLD PLENUM
18. INTAKE MANIFOLD PLENUM 

GASKET

19. VACUUM PIPE
20. EVAPORATIVE EMISSION 

PURGE SOLENOID

21. EXHAUST GAS RECIRCULATION 

VALVE

22. GASKET
23. HARNESS BRACKET
24. MANIFOLD ABSOLUTE 

PRESSURE SENSOR

25. O-RING

REMOVAL STEPS (Continued)

AC306688

INTAKE MANIFOLD
PLENUM GASKET

MD998412

AB

INTAKE MANIFOLD

TSB Revision

INTAKE AND EXHAUST

15-8

INTAKE MANIFOLD

REMOVAL AND INSTALLATION <2.4L ENGINE>

M1151003000813

Pre-removal Operation
• Fuel Line Pressure Reduction [Refer to GROUP 13A, 

On-vehicle Service 

− Fuel Pump Connector Disconnec-

tion (How to Reduce Pressurized Fuel Lines) 

P.13A-1107

].

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

Service 

− Engine Coolant Replacemen

P.14-7

).

• Air Cleaner Cover and Air Intake Hose Removal (Refer to 

P.15-4

).

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

Body 

P.13A-1119

).

• Delivery Pipe and Injector Assembly Removal (Refer to 

GROUP 13A, Injector 

P.13A-1117

).

Post-installation Operation
• Delivery Pipe and Injector Assembly Installation (Refer to 

GROUP 13A, Injector 

P.13A-1117

).

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

Body 

P.13A-1119

).

• Air Cleaner Cover and Air Intake Hose Installation (Refer 

to 

P.15-4

).

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

Service 

− Engine Coolant Replacement 

P.14-7

).

AC306677

11 ± 1 N·m
98 ± 8 in-lb

11 ± 1 N·m
98 ± 8 in-lb

11 ± 1 N·m
98 ± 8 in-lb

12 ± 2 N·m
102 ± 22 in-lb

5.0 ± 1.0 N·m
44 ± 9 in-lb

11 ± 1 N·m
98 ± 8 in-lb

11 ± 1 N·m
98 ± 8 in-lb

13 ± 1 N·m
115 ± 9 in-lb

24 ± 3 N·m
18 ± 2 ft-lb

20 ± 2 N·m
15 ± 1 ft-lb

31 ± 3 N·m
23 ± 2 ft-lb

24 ± 4 N·m
18 ± 3 ft-lb

24 ± 3 N·m
18 ± 2 ft-lb

31 ± 3 N·m
23 ± 2 ft-lb

1

19

18

17

16

15

14

13

12

10

9

8

7

6

5

11

4

3

2

20

21

N

N

3

(ENGINE OIL)

N

N

N

AB

INTAKE MANIFOLD

TSB Revision

INTAKE AND EXHAUST

15-9

REMOVAL SERVICE POINT

.

<<A>> RADIATOR LOWER HOSE DISCONNECTION
Make mating marks on the radiator hose and the hose clamp. 
Disconnect the radiator hose.

REMOVAL STEPS

1. EXHAUST GAS RECIRCULATION 

VALVE

>>D<<

2. EXHAUST GAS RECIRCULATION 

VALVE GASKET

>>C<<

3. BRAKE BOOSTER VACUUM HOSE
4. BRAKE BOOSTER VACUUM PIPE
5. PRESSURE HOSE CLAMP
6. EVAPORATIVE EMISSION VACUUM 

HOSE CONNECTION

7. MANIFOLD ABSOLUTE PRESSURE 

SENSOR CONNECTOR

8. HARNESS CRAMP
9. KNOCK SENSOR CONNECTOR 

BRACKET

10. ENGINE OIL DIPSTICK AND 

DIPSTICK GUIDE

11. O-RING

<<A>> >>B<<

12. RADIATOR LOWER HOSE 

CONNECTION

13. HEATER WATER HOSE 

CONNECTION

>>A<<

14. THERMOSTAT CASE ASSEMBLY
15. O-RING
16. MANIFOLD ABSOLUTE PRESSURE 

SENSOR

17. O-RING
18. INTAKE MANIFOLD STAY
19. INTAKE MANIFOLD
20. INTAKE MANIFOLD GASKET
21. EVAPORATIVE EMISSION PURGE 

SOLENOID VALVE, EVAPORATIVE 
EMISSION VACUUM HOSE AND 
PIPE ASSEMBLY

REMOVAL STEPS (Continued)

AC200641AB

MATING MARKS

INTAKE MANIFOLD

TSB Revision

INTAKE AND EXHAUST

15-10

INSTALLATION SERVICE POINTS

.

>>A<< THERMOSTAT CASE ASSEMBLY INSTALLATION
1. Use a gasket scraper or wire brush to completely eliminate 

all gasket material on the gasket mounting surface.

2. Apply a bead of the sealant to the cylinder head mating 

surface of the thermostat case assembly as shown.

Specified Sealant: 3M

 AAD Part No.8672, 3M AAD 

part No.8679/8678 or equivalent

3. Apply sealant to the thread of the thermostat case assembly 

bolts as shown.

Specified Sealant: 3M

 AAD Part No.8730, 8731 or 

equivalent

4. With the sealant still wet (within 15 minutes after the sealant 

is applied), install the thermostat case assembly. Do not 
apply the sealant in an area more than the required.

.

>>B<< RADIATOR LOWER HOSE CONNECTION
1. Insert each hose as far as the projection of the water inlet 

fitting.

2. Align the mating marks on the radiator hose and hose 

clamp, and then connect the radiator hose.

.

>>C<< BRAKE BOOSTER VACUUM HOSE CONNECTION
Insert vacuum hose with its paint mark facing upward.

.

AC305212

φ 3 mm
(0.12 in)

AC

THERMOSTAT CASE
ASSEMBLY

AC303724AC

THERMOSTAT CASE ASSEMBLY

AC200642

MATING
MARKS

PROJECTION

WATER INLET 
FITTING 

AE

AC305104

AC

PAINT MARK

PAINT MARK

 

 

 

 

 

 

 

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