Mitsubishi Montero Sport (2004+). Manual - part 590

EXHAUST MANIFOLD

TSB Revision

INTAKE AND EXHAUST

15-9

EXHAUST MANIFOLD

REMOVAL AND INSTALLATION

M1151003300706

INSPECTION

M1151003400349

Check the following points; replace the part if a problem is 
found.

.

Exhaust Manifold Check
1. Check for damage or cracking of any part.
2. Using a straight edge and a 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)

Pre-removal and Post-installation Operation
• Front Catalytic Converter <R.H. and L.H.> Removal and 

Installation (Refer to 

P.15-10

).

AC004651

12 - 15 N·m
106 - 133 in-lb

12 - 15 N·m
106 - 133 in-lb

44 N·m
33 ft-lb

44 N·m
33 ft-lb

18 N·m
13 ft-lb

59 N·m
43 ft-lb

1

2

3

4

5

6

7

N

N

N

AB

REMOVAL STEPS

1.

HEAT PROTECTOR <R.H.>

2.

EXHAUST MANIFOLD <R.H.>

3.

EXHAUST MANIFOLD GASKET 
<R.H.>

4.

EGR PIPE

5.

HEAT PROTECTOR <L.H.>

6.

EXHAUST MANIFOLD <L.H.>

7.

EXHAUST MANIFOLD GASKET 
<L.H.>

REMOVAL STEPS (Continued)

EXHAUST PIPE AND MAIN MUFFLER

TSB Revision

INTAKE AND EXHAUST

15-10

EXHAUST PIPE AND MAIN MUFFLER

REMOVAL AND INSTALLATION

M1151008700356

Required Special Tool:

• MD998770: Oxygen sensor wrench

REMOVAL SERVICE POINT

.

<<A>> HEATED OXYGEN SENSOR REMOVAL
Use special tool MD998770 to remove the heated oxygen sen-
sor.

AC309257

AC309256

13 N·m
115 in-lb

44 N·m
33 ft-lb

49 N·m
35 ft-lb

49 N·m
35 ft-lb

25 N·m
18 ft-lb

25 N·m
18 ft-lb

49 N·m
35 ft-lb

49 N·m
35 ft-lb

2

1

2

2

3

3

4

9

10

6

7

5

5

5

13

11

N

N

N

5

2, 9

AB

14

12

8

25 N·m
18 ft-lb

MAIN MUFFLER REMOVAL 
STEPS

1.

MAIN MUFFLER

2.

HANGER

3.

PROTECTOR
CENTER EXHAUST PIPE 
REMOVAL STEPS

4.

CENTER EXHAUST PIPE

8.

GASKET

9.

HANGER

10. PROTECTOR

REAR CATALYTIC CONVERTER 
REMOVAL STEPS

6.

COMPRESSION SPRING

7.

REAR CATALYTIC CONVERTER

8.

GASKET

FRONT CATALYTIC CONVERTER 
REMOVAL STEPS

•

Under Cover and Skid Plate (Refer 
to GROUP 42, Under Cover 

P.42-207

)

<<A>>

>>A<<

5.

HEATED OXYGEN SENSOR

6.

COMPRESSION SPRING

11. FRONT CATALYTIC CONVERTER 

(L.H.)

12. GASKET
13. FRONT CATALYTIC CONVERTER 

(R.H.)

14. GASKET

ACX02426 AB

MD998770

SPECIFICATIONS

TSB Revision

INTAKE AND EXHAUST

15-11

INSTALLATION SERVICE POINT

.

>>A<< HEATED OXYGEN SENSOR INSTALLATION
Use special tool MD998770 to installation the heated oxygen 
sensor.

SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

M1151006800409

ACX02426 AB

MD998770

ITEM

SPECIFICATION

Air cleaner
Air cleaner and resonator bolt

8.8 N

⋅m (78 in-lb)

Air cleaner bracket bolt

3.9 N

⋅m (35 in-lb)

Air flow sensor nut

8.8 N

⋅m (78 in-lb)

Air intake hose clamp bolt

3.9 N

⋅m (35 in-lb)

Exhaust manifold
EGR pipe bolt

18 N

⋅m (13 ft-lb)

EGR pipe flare nut

59 N

⋅m (43 ft-lb)

Exhaust manifold nut

44 N

⋅m (33 ft-lb)

Heat protector bolt

12 

− 15 N⋅m (106 − 133 in-lb)

Exhaust pipe and main muffler
Center exhaust pipe bolt

49 N

⋅m (35 ft-lb)

Exhaust bracket bolt

25 N

⋅m (18 ft-lb)

Front catalytic converter bolt

25 N

⋅m (18 ft-lb)

Front catalytic converter nut

49 N

⋅m (35 ft-lb)

Hanger bolt

13 N

⋅m (115 in-lb)

Heated oxygen sensor

44 N

⋅m (33 ft-lb)

Main muffler bolt

25 N

⋅m (18 ft-lb)

Rear catalytic converter bolt

49 N

⋅m (35 ft-lb)

Tail pipe bolt

49 N

⋅m (35 ft-lb)

Intake manifold
Accelerator cable bracket bolt

M6

10 

− 12 N⋅m (89 − 106 in-lb)

M8

18 N

⋅m (13 ft-lb)

Air intake fitting bolt and nut

18 N

⋅m (13 ft-lb)

SPECIFICATIONS

TSB Revision

INTAKE AND EXHAUST

15-12

SERVICE SPECIFICATION

M1151000300257

A/T oil dipstick assembly

24 N

⋅m (18 ft-lb)

EGR pipe bolt

18 N

⋅m (13 ft-lb)

EGR valve bolt

22 N

⋅m (16 ft-lb)

Fuel pressure regulator bolt

8.8 N

⋅m (78 in-lb)

Fuel rail bolt

12 N

⋅m (106 in-lb)

High-pressure fuel hose bolt

4.9 N

⋅m (43 in-lb)

Intake manifold nut

20 

− 23 N⋅m (14 − 17 ft-lb)

Intake manifold plenum stay bolt

M8

18 N

⋅m (13 ft-lb)

M10

35 N

⋅m (26 ft-lb)

Ignition power transistor bolt

M8 

× 18

17 

− 20 N⋅m (12 − 14 ft-lb)

M8 

× 80, M8 × 50

18 N

⋅m (13 ft-lb)

Manifold absolute pressure sensor bolt

4.9 N

⋅m (43 in-lb)

Solenoid bracket bolt

8.8 N

⋅m (78 in-lb)

Upper intake manifold bolt

18 N

⋅m (13 ft-lb)

Vacuum control valve bracket and vacuum hose clamp bolt

10 

− 12 N⋅m (89 − 106 in-lb)

Water outlet fitting bracket bolt

17 

− 20 N⋅m (12 − 14 ft-lb)

Water pump bracket bolt

24 N

⋅m (17 ft-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)