Mitsubishi Montero (2002-2004). Manual - part 1081

EXHAUST PIPE AND MAIN MUFFLER

TSB Revision

INTAKE AND EXHAUST

15-13

Standard value: 0.15 mm (0.006 inch) or less 
Limit: 0.20 mm (0.008 inch)

EXHAUST PIPE AND MAIN MUFFLER

REMOVAL AND INSTALLATION

M1151008700152

Required Special Tool:

• MD998770: Oxygen sensor wrench

Pre-removal and Post-installation Operation
Front Under Cover Removal and Installation

AC204061

49 ± 10 N·m
37 ± 7 ft-lb

49 ± 4 N·m
37 ± 3 ft-lb

49 ± 10 N·m
37 ± 7 ft-lb

25 ± 4 N·m
18 ± 3 ft-lb

49 ± 10 N·m
37 ± 7 ft-lb

9.0 ± 2.0 N·m
79 ± 18 in-lb

49 ± 10 N·m
37 ± 7 ft-lb

13 ± 2 N·m
111 ± 22 in-lb

44 ± 5 N·m
33 ± 3 ft-lb

13 ± 2 N·m
111 ± 22 in-lb

13 ± 2 N·m
111 ± 22 in-lb

13 ± 2 N·m
111 ± 22 in-lb

49 ± 10 N·m
37 ± 7 ft-lb

8,10,11,12

2,6

8

9

17

12

11

14

13

10

15

18

6

7

5

6

6

16

1

3

2

2

4

3

N

N

N

N

N

AB

TAIL PIPE REMOVAL STEPS

1. TAIL PIPE
2. HANGER
3. HANGER BRACKET
4. REAR FLOOR HEAT PROTECTOR

MAIN MUFFLER REMOVAL STEPS

5. MAIN MUFFLER
6. HANGER
7. HANGER BRACKET

FRONT EXHAUST PIPE REMOVAL 
STEPS

<<A>> >>A<<

8. RIGHT BANK HEATED OXYGEN 

SENSOR (FRONT)

9. FRONT EXHAUST PIPE

<<A>> >>A<<

10. RIGHT BANK HEATED OXYGEN 

SENSOR (REAR)

<<A>> >>A<<

11. LEFT BANK HEATED OXYGEN 

SENSOR (REAR)

<<A>> >>A<<

12. LEFT BANK HEATED OXYGEN 

SENSOR (FRONT)

13. WARM-UP THREE-WAY CATALYTIC 

CONVERTER

14. BRACKET
15. SEAL RING
16. CATALYTIC CONVERTER
17. DASH HEAT PROTECTOR
18. FRONT FLOOR HEAT PROTECTOR

FRONT EXHAUST PIPE REMOVAL 
STEPS (Continued)

EXHAUST PIPE AND MAIN MUFFLER

TSB Revision

INTAKE AND EXHAUST

15-14

REMOVAL SERVICE POINT

.

<<A>> RIGHT BANK HEATED OXYGEN SENSOR (FRONT)/
RIGHT BANK HEATED OXYGEN SENSOR (REAR)/LEFT 
BANK HEATED OXYGEN SENSOR (REAR)/LEFT BANK 
HEATED OXYGEN SENSOR (FRONT) REMOVAL
Use special tool MD998770 to remove the oxygen sensor.

INSTALLATION SERVICE POINT

.

>>A<< LEFT BANK HEATED OXYGEN SENSOR (FRONT)/
LEFT BANK HEATED OXYGEN SENSOR (REAR)/RIGHT 
BANK HEATED OXYGEN SENSOR (REAR)/RIGHT BANK 
HEATED OXYGEN SENSOR (FRONT) INSTALLATION
Use special tool MD998770 to install the oxygen sensor.

ACX02426 AB

MD998770

ACX02426 AB

MD998770

SPECIFICATIONS

TSB Revision

INTAKE AND EXHAUST

15-15

SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

M1151006800283

ITEM

SPECIFICATION

Air cleaner
Air cleaner bolt

9.0 

± 1.0 N⋅m (80 ± 9 in-lb)

Air cleaner bracket bolt

9.0 

± 1.0 N⋅m (80 ± 9 in-lb)

Air duct bolt

5.0 

± 1.0 N⋅m (44 ± 9 in-lb)

Volume airflow sensor nut

9.0 

± 1.0 N⋅m (80 ± 9 in-lb)

Air intake hose clamp bolt

3.9 

± 1.0 N⋅m (35 ± 8 in-lb)

Exhaust manifold
A/T oil dipstick guide to engine hanger bolt

24 

± 4 N⋅m (18 ± 3 ft-lb)

A/T oil dipstick guide to transmission bolt

44 

± 8 N⋅m (33 ± 5 ft-lb)

EGR pipe bolt

18 

± 2 N⋅m (13 ± 2 ft-lb)

EGR pipe flare nut

59 

± 10 N⋅m (44 ± 7 ft-lb)

Engine oil dipstick guide bolt

44 

± 5 N⋅m (33 ± 3 ft-lb)

Exhaust manifold nut

14 

± 1 N⋅m (120 ± 13 in-lb)

Heat protector bolt

14 

± 1 N⋅m (120 ± 13 in-lb)

Exhaust pipe and main muffler
Bracket bolt

49 

± 10 N⋅m (37 ± 7 ft-lb)

Warm-up three-way catalytic converter bolt

49 

± 4 N⋅m (37 ± 3 ft-lb)

Warm-up three-way catalytic converter nut

49 

± 10 N⋅m (37 ± 7 ft-lb)

Front exhaust pipe bolt

25 

± 4 N⋅m (18 ± 3 ft-lb)

Front exhaust pipe nut

49 

± 10 N⋅m (37 ± 7 ft-lb)

Ground cable bolt

9.0 

± 2.0 N⋅m (79 ± 18 in-lb)

Hanger bolt

13 

± 2 N⋅m (111 ± 22 in-lb)

Heated oxygen sensor

44 

± 5 N⋅m (33 ± 3 ft-lb)

Main muffler bolt

49 

± 10 N⋅m (37 ± 7 ft-lb)

Main muffler nut

49 

± 10 N⋅m (37 ± 7 ft-lb)

Intake manifold
Control wiring harness clamp bolt

11 

± 1 N⋅m (98 ± 8 in-lb)

EGR pipe

59 

± 10 N⋅m (44 ± 7 ft-lb)

EGR pipe bolt

18 

± 2 N⋅m (13 ± 2 ft-lb)

EGR valve bolt

24 

± 3 N⋅m (18 ± 2 ft-lb)

Evaporative emission purge solenoid valve bolt

9.0 

± 1.0 N⋅m (80 ± 9 in-lb)

Fuel high-pressure hose bolt

5.0 

± 1.0 N⋅m (44 ± 9 in-lb)

Fuel pipe bolt

9.0 

± 1.0 N⋅m (80 ± 9 in-lb)

Fuel pressure regulator bolt

9.0 

± 2.0 N⋅m (80 ± 17 in-lb)

Fuel rail bolt

12 

± 1 N⋅m (102 ± 13 in-lb)

Intake manifold tuning valve bolt and nut

9.0 

± 1.0 N⋅m (80 ± 9 in-lb)

Injector wiring harness connector clamp bolt

11 

± 1 N⋅m (98 ± 8 in-lb)

SPECIFICATIONS

TSB Revision

INTAKE AND EXHAUST

15-16

SERVICE SPECIFICATION

M1151000300321

Intake manifold nut

22 

± 1 N⋅m (16 ± 1 ft-lb)

Intake manifold plenum stay bolt

M8

18 

± 2 N⋅m (13 ± 2 ft-lb)

M10

36 

± 6 N⋅m (27 ± 5 ft-lb)

Intake manifold plenum bolt

18 

± 2 N⋅m (13 ± 2 ft-lb)

Manifold differential pressure sensor bolt

5.0 

± 1.0 N⋅m (44 ± 9 in-lb)

Knock sensor and camshaft position sensor connector clamp bolt

11 

± 1 N⋅m (98 ± 8 in-lb)

Solenoid valve and vacuum hose bracket bolt

9.0 

± 1.0 N⋅m (80 ± 9 in-lb)

Water outlet fitting bracket bolt

14 

± 1 N⋅m (120 ± 13 in-lb)

ITEM

SPECIFICATION

ITEM

STANDARD VALUE

LIMIT

Manifold distortion of the installation surface   mm (in) 0.15 (0.006) or less

0.20 (0.008)