Mitsubishi Montero Sport (2004+). Manual - part 135

INTAKE MANIFOLD AND FUEL PARTS

TSB Revision

ENGINE OVERHAUL

11B-15

INTAKE MANIFOLD AND FUEL PARTS

REMOVAL AND INSTALLATION

M1113004300198

AK302422AB

11 ± 1 N·m
97 ± 9 in-lb

13 ± 2 N·m
115 ± 18 in-lb

29 ± 10 N·m
21 ± 7 ft-lb

19 ± 1 N·m
14 ± 1 ft-lb

24 ± 4 N·m
18 ± 3 ft-lb

19 ± 1 N·m
14 ± 1 ft-lb

4

5

6

3

9

10

11

7

12

13

14

15

16

17

18

8

7

5

13 ± 2 N·m
115 ± 18 in-lb

19 ± 1 N·m
14 ± 1 ft-lb

1

2

REMOVAL STEPS

>>G<<

1.

ENGINE COOLANT 
TEMPERATURE GAUGE UNIT

>>F<<

2.

ENGINE COOLANT 
TEMPERATURE SENSOR

3.

WATER OUTLET FITTING

4.

WATER OUTLET FITTING GASKET

5.

WATER HOSE

>>D<<

6.

WATER OUTLET PIPE

>>D<<

7.

O-RING

8.

WATER HOSE <Vehicles for 
Canada>

9.

BREATHER AND WATER HOSE 
ASSEMBLY <Vehicles other than 
Canada>

10. WATER INLET FITTING

>>E<<

11. THERMOSTAT
12. THERMOSTAT CASE
13. THERMOSTAT CASE GASKET
14. WATER PASSAGE
15. WATER PASSAGE GASKET

>>D<<

16. WATER PIPE

>>D<<

17. O-RING
18. WATER HOSE

REMOVAL STEPS (Continued)

INTAKE MANIFOLD AND FUEL PARTS

TSB Revision

ENGINE OVERHAUL

11B-16

AK000435

12 ± 1 N·m
106 ± 9 in-lb

20 – 23 N·m
15 – 17 ft-lb

8.8 ± 1.0 N·m
78 ± 9 in-lb

9 ± 1 N·m
80 ± 9 in-lb

20

21

22

23

24

25

27

28

29

30

31

32

33

AD

24 ± 3 N·m
18 ± 2 ft-lb

19

26

REMOVAL STEPS

19. INJECTOR HARNESS
20. INJECTOR AND FUEL RAIL
21. INSULATOR

>>C<<

22. FUEL PRESSURE REGULATOR
23. O-RING
24. INSULATOR

>>B<<

25. INJECTOR
26. O-RING

27. GROMMET
28. FUEL PIPE
29. O-RING
30. FUEL RAIL
31. WATER PUMP BRACKET

>>A<<

32. INTAKE MANIFOLD
33. INTAKE MANIFOLD GASKET

REMOVAL STEPS (Continued)

INTAKE MANIFOLD AND FUEL PARTS

TSB Revision

ENGINE OVERHAUL

11B-17

INSTALLATION SERVICE POINTS

.

>>A<< INTAKE MANIFOLD INSTALLATION
1. Tighten the nuts on the right bank to 6.5 

± 1 N⋅m 58 ± 9 

in-lb).

2. Tighten the nuts on the left bank to the specified torque.

Tightening torque: 20 

− 23 N⋅m (15 − 17 ft-lb)

3. Tighten the nuts on the right bank to the specified torque.

Tightening torque: 20 

− 23 N⋅m (15 − 17 ft-lb)

4. Tighten the nuts on the left bank and those on the right bank 

again in that order.

Tightening torque: 20 

− 23 N⋅m (15 − 17 ft-lb)

.

>>B<< INJECTOR INSTALLATION

CAUTION

Use care not to let engine oil enter the fuel rail.
1. Before installing the injector, lubricate the O-ring with a drop 

of new engine oil for easy installation.

2. Insert the injector top end into the fuel rail. Be careful not to 

damage the O-ring during installation.

.

>>C<< FUEL PRESSURE REGULATOR INSTALLATION 

CAUTION

Do not let engine oil enter the fuel rail.
Before installing the pressure regulator, lubricate the O-ring 
with a drop of new engine oil for easy installation.

.

>>D<< O-RING AND WATER PIPE INSTALLATION 

CAUTION

Keep the O-ring free of oil or grease.
Wet the O-ring (with water) to easy assembly.

.

AKX00680

TIMING
BELT SIDE

NUT "R"

NUT "L"

AB

AKX00748

FUEL RAIL

INJECTOR

AB

AKX00711

O-RING

WATER INLET 
PIPE

AB

INTAKE MANIFOLD AND FUEL PARTS

TSB Revision

ENGINE OVERHAUL

11B-18

>>E<< THERMOSTAT INSTALLATION
Install the thermostat in the thermostat case with its jiggle valve 
located at the top position.

.

>>F<< SEALANT APPLICATION TO ENGINE COOLANT 
TEMPERATURE SENSOR 
Apply 3M

 AAD Part number 8731 or equivalent to the engine 

coolant temperature sensor.

.

>>G<< SEALANT APPLICATION TO ENGINE COOLANT 
TEMPERATURE GAUGE UNIT 
Apply 3M

 AAD Part number 8672 or equivalent to the engine 

coolant temperature gauge unit.

AKX01453

JIGGLE
VALVE

AB

AKX00686

AKX00687