Mitsubishi Outlander GS45X. Manual - part 1234

GENERATOR AND IGNITION SYSTEM

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-11

Required Special Tool:

• MB991883: Flywheel Stopper

• MB991398: Spark plug wrench

REMOVAL SERVICE POINTS

.

<<A>> CRANKSHAFT PULLEY CENTER BOLT 
REMOVAL

1. Use special tool MB991883, to secure the drive plate.
2. Remove the crankshaft pulley center bolt.

.

<<B>> SPARK PLUG REMOVAL

Using special tool MB991398, removal the spark plug.

INSTALLATION SERVICE POINTS

.

>>A<< SPARK PLUG INSTALLATION

Use special tool MB991398, tighten the spark plug to specified 
tightening torque.

Tightening torque: 25 

± 5 N⋅m (18 ± 4 ft-lb)

.

AK502869AD

MB991883

AK600875

MB991398

AB

Spark plug

AK600875

MB991398

AB

Spark plug

GENERATOR AND IGNITION SYSTEM

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-12

>>B<< CRANKSHAFT PULLEY / CRANKSHAFT 
PULLEY WASHER / CRANKSHAFT PULLEY 
CENTER BOLT INSTALLATION

1. Use special tool MB991883, to secure the drive plate.

2. Wipe the dirt on the crankshaft pulley washer and on the 

thread hole of the crankshaft using a rag.

3. Wipe the dirt on the crankshaft pulley and the crankshaft 

sprocket using a rag, and then remove the grease from the 
portion shown in the illustration.
NOTE: Remove grease to prevent the coefficient of friction 
of the pressing portion from declining due to adhesion of oil.

4. Install the crankshaft pulley.
5. Apply an appropriate and minimum amount of engine oil to 

the threaded portion of the crankshaft and lower part of the 
flange.

6. With the chamfered side on the inside of the crankshaft 

pulley washer facing the bolt top, install the crankshaft pulley 
washer to the crankshaft pulley center bolt.

7. Tighten the crankshaft pulley center bolt to the specified 

tightening torque.

Tightening torque: 210 N

⋅m (155 ft-lb)

.

AK503335

AD

MB991883

AK602911

AD

Engine front

Washer

Crankshaft

Crankshaft pulley

Crankshaft 
pulley bolt

Crankshaft
sprocket

: Wipe clean with a rag.
: Wipe clean with a rag and degrease.
: Wipe clean with a rag, degrease and 
 apply a small amount of engine oil.

GENERATOR AND IGNITION SYSTEM

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-13

>>C<< GENERATOR / POWER STEERING PUMP 
BRACKET INSTALLATION

1. Temporarily tighten power steering pump bracket bolts.

CAUTION

Always loosen the power steering pump bracket bolt, and 
temporarily the alternator. Then tighten each bolt.
2. Loosen the power steering pump bracket bolt and make the 

power steering pump bracket unfixed.

3. Temporarily tighten alternator bolts.
4. Tighten them to the specified tightening torque according to 

the order as illustrated.

Tightening torque

Power steering pump bracket:

M8: 26 

± 3 N⋅m (19 ± 2 ft-lb)

M10: 44 

± 8 N⋅m (33 ± 5 ft-lb)

Generator: 44 

± 10 N⋅m (32 ± 7 ft-lb)

AK503383AG

Generator

1

2

3

4

5

Power steering 
pump bracket

80 mm 
(3.15 in)

80 mm 
(3.15 in)

THROTTLE BODY AND EGR SYSTEM

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ENGINE OVERHAUL <2.4L ENGINE>

11B-14

THROTTLE BODY AND EGR SYSTEM

REMOVAL AND INSTALLATION

M1113032700397

AK900247AB

10

11

12

13

16

15

17

18

19

14

7

20

21

4

3

2

1

5

11 ± 1 N·m
98 ± 8 in-lb

22

23

8

9.5 ± 2.5 N·m
84 ± 22 in-lb

9

20 ± 2 N·m
15 ± 1 ft-lb

24 ± 3 N·m
18 ± 1 ft-lb

4.0 ± 1.0 N·m
36 ± 8 in-lb

6

20 ± 2 N·m
15 ± 1 ft-lb

20 ± 2 N·m
15 ± 1 ft-lb

20 ± 2 N·m
15 ± 1 ft-lb

20 ± 2 N·m
15 ± 1 ft-lb

24 ± 3 N·m
18 ± 1 ft-lb

4.0 ± 1.0 N·m
36 ± 8 in-lb

Removal steps 

1. Vacuum pipe and hose
2. Purge hose
3. Chamber
4. Purge hose
5. Purge hose
6. Water hose
7. Throttle body stay

>>D<<

8. Throttle body

>>D<<

9. Throttle body gasket

>>C<<

10. Exhaust gas recirculation valve

>>C<<

11. Exhaust gas recirculation valve 

gasket

>>B<<

12. EGR pipe
13. EGR pipe gasket

14. Exhaust gas recirculation valve 

support gasket

>>B<<

15. EGR support stay A

>>B<<

16. EGR support stay B

>>B<<

17. Exhaust gas recirculation valve 

support

18. EGR inlet pipe gasket
19. EGR inlet pipe
20. Solenoid valve
21. O-ring

>>A<<

22. Manifold absolute pressure (MAP) 

sensor

23. O-ring

Removal steps (Continued)