Mitsubishi Galant (2004+). Manual - part 1660

INTAKE MANIFOLD

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INTAKE AND EXHAUST

15-11

>>D<< EXHAUST GAS RECIRCULATION VALVE GASKET 
INSTALLATION
Install the exhaust gas recirculation valve gasket as shown in 
the illustration.

AC302358AC

GASKET

NOTCHED
PART

NOTCHED
PART

INTAKE MANIFOLD

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INTAKE AND EXHAUST

15-12

REMOVAL AND INSTALLATION <3.8L ENGINE>

M1151003000802

Pre-removal Operation
• Fuel Discharge Prevention [Refer to GROUP 13B, 

On-vehicle Service 

− Fuel Pump Relay Disconnection 

(How to Reduce Pressurized Fuel Lines) 

P.13B-1136

.]

• Intake Manifold Plenum Removal (Refer to 

P.15-6

.)

Post-installation Operation
• Intake Manifold Plenum Installation (Refer to 

P.15-6

.)

• Fuel Leakage Inspection

AC306908

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

14 ± 1 N·m
120 ± 13 in-lb

12 ± 1 N·m
102 ± 13 in-lb

36 ± 6 N·m
27 ± 4 ft-lb

24 ± 3 N·m
18 ± 2 ft-lb

1

1

2

12

10

3

4

22 ± 1 N·m
16 ± 1 ft-lb

6

13

11

12

7

5

8

9

N

N

N

AB

3

4

6

INTAKE
MANIFOLD
MOUNTING
STAD

CYLINDER
HEAD

ENGINE OIL

14 ± 1 N·m
120 ± 13 in-lb

REMOVAL STEPS

1.

INJECTOR CONNECTOR

2.

ENGINE MOUNTING STAY

>>C<<

3.

FUEL HIGH-PRESSURE HOSE 
CONNECTION

4.

O-RING

5.

BLOW-BY HOSE

<<A>>

6.

FUEL RAIL AND INJECTOR

7.

PCV HOSE CONNECTION

8.

TIMING BELT FRONT UPPER 
COVER, RIGHT

9.

TIMING BELT FRONT UPPER 
COVER, LEFT

10. WATER PUMP BRACKET

>>B<<

11. INTAKE MANIFOLD

>>A<<

12. INTAKE MANIFOLD GASKET
13. CONTROL HARNESS CLAMP

REMOVAL STEPS (Continued)

INTAKE MANIFOLD

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INTAKE AND EXHAUST

15-13

REMOVAL SERVICE POINT

.

<<A>> FUEL RAIL AND INJECTOR REMOVAL

CAUTION

Care must be taken when removing the fuel rail not to drop 
the injector.
Remove the fuel rail with the injectors attached to it.

INSTALLATION SERVICE POINTS

.

>>A<< INTAKE MANIFOLD GASKET INSTALLATION
Install the gasket with the protrusions in the position illustrated.

.

>>B<< INTAKE MANIFOLD INSTALLATION
1. Coat the intake manifold mounting studs with engine oil.
2. Tighten the intake manifold mounting nuts by the following 

procedure.

.

>>C<< FUEL HIGH-PRESSURE HOSE INSTALLATION

CAUTION

• Be careful not to allow any engine oil to enter the fuel 

rail.

• Be careful not to bend the fuel high-pressure hose as it 

is made of plastics.

1. When connecting the fuel high-pressure hose to the fuel rail, 

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

2. While turning the fuel high-pressure hose to the left and 

right, install it to the fuel rail.

3. Check that the injector turns smoothly. If it does not turn 

smoothly, the O-ring may be trapped. Remove the fuel 
high-pressure hose and then re-insert it into the fuel rail and 
check again.

ACX02434 AC

PROTRUSION

PROTRUSION

FRONT OF VEHICLE

ORDER MOUNTING NUTS TIGHTENING TORQUE 

1st

Right-bank nuts

6.5 

± 1.5 N⋅m (58 ± 13 in-lb)

2nd

Left-bank nuts

22 

± 1 N⋅m (16 ± 1 ft-lb)

3rd

Right-bank nuts

22 

± 1 N⋅m (16 ± 1 ft-lb)

4th

Left-bank nuts

22 

± 1 N⋅m (16 ± 1 ft-lb)

5th

Right-bank nuts

22 

± 1 N⋅m (16 ± 1 ft-lb)

AC001433

RIGHT BANK

LEFT BANK

AB

AC206397

FUEL HIGH-
PRESSURE
HOSE

O-RING

FUEL RAIL

AB

INTAKE MANIFOLD

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INTAKE AND EXHAUST

15-14

INSPECTION

M1151003100672

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. 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 (0.006 inch) or less 
Limit: 0.20 mm (0.008 inch)