Mitsubishi Montero Sport (2004+). Manual - part 588

 

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Mitsubishi Montero Sport (2004+). Manual - part 588

 

 

GENERAL DESCRIPTION

TSB Revision

INTAKE AND EXHAUST

15-2

GENERAL DESCRIPTION

M1151000100286

The exhaust pipe is divided into four parts.

INTAKE AND EXHAUST DIAGNOSIS

INTRODUCTION

M1151006900235

Intake leaks usually create driveability issues that 
are not obviously related to the intake system. 
Exhaust leaks or abnormal noise is caused by 
cracks, gaskets and fittings, or by when the exhaust 
pipe or muffler is damaged due to impacts during 
travel. The exhaust leaks from these sections and 
causes the exhaust noise to increase. There may be 
cases when the system contacts the body and vibra-
tion noise is generated.

TROUBLESHOOTING STRATEGY

M1151007000235

Use these steps to plan your diagnostic strategy. If 
you follow them carefully, you will be sure that you 
have exhausted most of the possible ways to find an 
intake or exhaust system fault.
1. Gather information from the customer.

2. Verify that the condition described by the 

customer exists.

3. Find the malfunction by following the Symptom 

Chart.

4. Verify that the malfunction is eliminated.

SYMPTOM CHART

M1151007100232

SYMPTOM PROCEDURES

INSPECTION PROCEDURE 1: Exhaust Leakage

DIAGNOSIS

STEP 1. Start the engine. Have an assistant stay 
in the driver’s seat. Raise the vehicle on a hoist. 
Have the assistant rev the engine while 
searching for exhaust leaks.

Q: Is the exhaust leaking?

YES : 

Go to Step 2.

NO : 

The procedure is complete.

STEP 2. Check the gasket for cracks, damage.

Q: Is the gasket damaged?

YES : 

Replace the gasket, then go Step 1.

NO : 

Go to Step 3.

STEP 3. Check for loosening in each coupling 
section.

Q: Is there any loosening in each section?

YES : 

Tighten, then go to Step 1.

NO : 

There is no action to be taken.

SYMPTOM

INSPECTION PROCEDURE

REFERENCE PAGE

Exhaust Leakage

1

P.15-2

Abnormal Noise

2

P.15-3

SPECIAL TOOL

TSB Revision

INTAKE AND EXHAUST

15-3

INSPECTION PROCEDURE 2: Abnormal Noise 

DIAGNOSIS

STEP 1. Start the engine. Have an assistant stay 
in the driver’s seat. Raise the vehicle on a hoist. 
Have the assistant rev the engine while 
searching for exhaust leaks.

Q: Is any abnormal noise generated?

YES : 

Go to Step 2.

NO : 

The procedure is complete.

STEP 2. Check for missing parts in the muffler. 
Tap the muffler lightly to check for loose baffles, 
etc.

Q: Are there any missing parts in the muffler? 

YES : 

Replace, then go to Step 1.

NO : 

Go to Step 3.

STEP 3. Check the hanger for cracks.

Q: Is the hanger cracked?

YES : 

Replace, then go to Step 1.

NO : 

Go to Step 4.

STEP 4. Check for interference of the pipes and 
muffler with the body.

Q: Are the pipes and muffler interfering with the 

body?

YES : 

Repair, then go to Step 1.

NO : 

Go to Step 5.

STEP 5. Check the heat protectors.

Q: Are any heat protectors loose or damaged?

YES : 

Tighten or replace, then go to Step 1.

NO : 

Go to Step 6.

STEP 6. Check the pipes, catalytic converters 
and muffler for damage.

Q: Are the pipes, catalytic converters and muffler 

damaged?

YES : 

Replace, then go to Step 1. (For the 

removal of the catalytic converter, refer to 
GROUP 17 

P.17-118

.)

NO : 

There is no action to be taken.

SPECIAL TOOL

M1151000600247

TOOL

TOOL NUMBER AND 
NAME

SUPERSESSION

APPLICATION

MD998770 
Oxygen sensor wrench

MD998770-01 or General 
service tool

Removal and installation 
of heated oxygen sensor

AIR CLEANER

TSB Revision

INTAKE AND EXHAUST

15-4

AIR CLEANER

REMOVAL AND INSTALLATION

M1151002100549

AC309265

3.9 N·m
35 in-lb

3.9 N·m
35 in-lb

3.9 N·m
35 in-lb

8.8 N·m
78 in-lb

8.8 N·m
78 in-lb

7

2

1

3

4

5

6

2

AB

REMOVAL STEPS

1.

AIR INTAKE HOSE

2.

RESONATOR

3.

AIR FLOW SENSOR ASSEMBLY

4.

AIR CLEANER COVER

5.

AIR CLEANER ELEMENT

6.

AIR CLEANER BODY

7.

AIR CLEANER BRACKET

REMOVAL STEPS (Continued)

 

 

 

 

 

 

 

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