Mitsubishi Outlander GS45X. Manual - part 1236

INTAKE MANIFOLD AND FUEL SYSTEM

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-19

.

>>E<< O-RING INSTALLATION 

1. Apply gasoline to the O-ring.
2. When inserting an O-ring into the injector on the injection 

nozzle side, use special tool MB992106 to gradually expand 
the O-ring, and fit it in place.

.

>>F<< INJECTOR AND INJECTOR SUPPORT 
INSTALLATION

CAUTION

Do not allow gasoline to enter the delivery pipe.
1. Apply gasoline to the O-ring of the injector.
2. Insert the injector into the delivery pipe while rotating the 

injector from side to side, taking care not to damage the 
O-ring.

3. Check that the injector rotates smoothly. If it does not rotate 

smoothly, the O-ring may be caught. Remove the injector 
and check the O-ring for damage. Then, insert it again into 
the delivery pipe and check.

4. Make sure that the protrusion of the injector is at the center 

as shown in the illustration.

5. Securely assemble the injector to the injector groove and 

delivery pipe collar.

.

AK600790

MB992106

O-ring

AC

AK502744

AK800066

INTAKE MANIFOLD AND FUEL SYSTEM

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-20

>>G<< FUEL RAIL ASSEMBLY / BRACKET / 
INJECTOR PROTECTOR REAR INSTALLATION

1. Install the delivery pipe assembly, bracket and injector 

protector rear on the cylinder head.

2. Tighten mounting bolts together with temporarily tightened 

inlet manifold mounting bolts in the order shown in the 
illustration.

3. Tighten the delivery pipe assembly, bracket, injector 

protector rear and inlet manifold in the order shown in the 
illustration.

Temporaliy torque: 3.5 

± 1.5 N⋅m (31 ± 13 in-lb)

Tightening torque: 20 

± 2 N⋅m (15 ± 1 ft-lb)

AK302000AH

1

2

3

4

5

6

7

8

9

10

AK502925AH

EXHAUST MANIFOLD

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-21

EXHAUST MANIFOLD

REMOVAL AND INSTALLATION

M1113011900846

<4WD>

AK502931AF

1

2

20 ± 5 N·m
15 ± 3 ft-lb

49 ± 5 N·m
36 ± 3 ft-lb

6

8

7

41 ± 10 N·m
30 ± 7 ft-lb

9

3

49 ± 6 N·m
36 ± 4 ft-lb

11 ± 1 N·m
98 ± 8 in-lb

4

14 ± 1 N·m
124 ± 8 in-lb

5

11 ± 1 N·m
98 ± 8 in-lb

14 ± 1 N·m
124 ± 8 in-lb

41 ± 10 N·m
30 ± 7 ft-lb

Removal steps 

>>C<<

1. Exhaust manifold bracket C

>>C<<

2. Exhaust manifold bracket A
3. Crankshaft position sensor cover

>>B<<

4. Crankshaft position sensor

>>B<<

5. O-ring

6. Exhaust manifold upper cover
7. Exhaust manifold lower cover
8. Exhaust manifold

>>A<

9. Exhaust manifold gasket

Removal steps (Continued)

EXHAUST MANIFOLD

TSB Revision

ENGINE OVERHAUL <2.4L ENGINE>

11B-22

<2WD - Except  vehicles for California>

AK603557AI

4

20 ± 5 N·m
15 ± 3 ft-lb

49 ± 5 N·m
36 ± 3 ft-lb

7

8

10

9

2

11 ± 1 N·m
98 ± 8 in-lb

5

6

14 ± 1 N·m
124 ± 8 in-lb

41 ± 10 N·m
30 ± 7 ft-lb

14 ± 1 N·m
124 ± 8 in-lb

41 ± 10 N·m
30 ± 7 ft-lb

3

11 ± 1 N·m
98 ± 8 in-lb

41 ± 10 N·m
30 ± 7 ft-lb

1

Removal steps 

>>C<<

1. Exhaust manifold bracket D

>>C<<

2. Exhaust manifold bracket B
3. Crankshaft position sensor cover

>>C<<

4. Exhaust manifold bracket A

>>B<<

5. Crankshaft position sensor

>>B<<

6. O-ring
7. Exhaust manifold upper cover
8. Exhaust manifold

>>A<

9. Exhaust manifold gasket
10.Exhaust manifold lower cover

Removal steps (Continued)