Replacing the intake manifold gasket for 4B12 and 4B11 Mitsubishi Outlander XL 2007 - 2012 engines

Tools:

• screw jack
• balloon wrench
• Screwdriver flat medium
• Phillips screwdriver, medium
• Ratchet wrench
• Extension (with cardan)
• Head 10 mm
• Head 12 mm
• torque wrench
• Open end wrench 10 mm
• Straight ring wrench 16 mm
• Pliers
• Marker
• Hex wrench for fixing the tensioner (or pin)
• Wheel chock (shoe)
• Knife (or scraper)

Parts and consumables:

• Intake manifold gasket 1542A133 - 4 pcs.

• Throttle assembly O-ring 1542A134 (if required)

• 1542A048 EGR Valve Servo Bracket O-Ring (If Required)

• Technical capacity
• Rope or wire
• Cleaner (or solvent)

• Hose
• Motor oil
• Coolant
• rags

Note:

The intake manifold gasket is considered the most vulnerable point of this vehicle assembly. Therefore, periodically it is required to replace it, which is quite simple to do on your own.
Replacing the intake manifold gasket is necessary in the following cases:

• when the engine is running, a characteristic whistle is heard;
• from under the hood comes the sound of "suction" (drivers with experience immediately pay attention to it);
• uneven operation of the motor and the inability of the engine to reach full power;
• at idle, the internal combustion engine is unstable;
• there is a leak of engine oil or coolant (sometimes these phenomena are recorded simultaneously).

The work to replace the intake manifold gasket on 4B12 and 4B11 engines is the same.

1.  Drain the coolant as described here . 

2.  Outlander HL engine is equipped with a decorative casing. To access the intake manifold, remove the shroud as described in  this article .

3.  Remove the accessory drive belt as described  here .

4.  Disconnect a wire from the plug "minus" of the storage battery.

5.  Remove the air filter assembly.

6.  Remove the throttle body assembly and remove the O-ring from the intake manifold flange groove.

7.  Remove the fuel manifold and injectors.

8.  Remove the EGR valve servo, EGR pipe and servo bracket assembly.

9.  Disconnect the engine management wiring harness from the sensors to clear the engine management wiring harness connectors and retainers from the intake manifold.

10.  Remove the EVAP vacuum hose from the canister purge solenoid valve and remove the hose from the intake manifold.

11.  Using pliers, remove the brake booster vacuum hose from the intake manifold pipe.

12.  Remove the power steering pump from the bracket along with the connected hoses.

Note:

After removal, use a rope or wire to hang the power steering pump assembly with hoses on the body in a place where they will not interfere with the removal of the intake manifold.

13.  Then disconnect the forced crankcase ventilation hose from the intake manifold.

14.  Remove the oil level indicator (dipstick).

15.  Turn away three bolts of fastening of a rack of an inlet collector and remove it.

16.  Turn away the left bolt of an inlet collector (bolt placement is shown at the removed inlet collector) and remove a forward protective casing of atomizers of a food system.

17.  Turn away the remained nuts and bolts of fastening of an inlet collector to a head of the block of cylinders and remove the inlet pipeline (on the removed collector placement of apertures for its fastening is visible).

18.  Remove the gaskets from the slots in the intake manifold.

19.  Install new intake manifold gaskets.

20.  Clean the mating surface of the block head under the intake manifold from deposits.

21.  Install the intake manifold assembly and front injector guard, temporarily tighten the bolts and nuts.

Note:

To avoid damage to the plastic intake manifold, the fuel rail fasteners, intake manifold assembly, and injector guards must be tightened in sequence.

22.  Establish a rack of an inlet collector and tighten bolts of fastening by hand. Make sure that the mating surface of the strut fits well on the intake manifold on one side and on the cylinder block on the other.

23.  Tighten the mounting bolts with a nominal torque of 20 ± 2 Nm, first from the intake manifold side, and then from the side of the cylinder block.

Note:

Do not overtighten the mounting bolts as this may damage the bolt threads in the plastic intake manifold.

24.  Then install all the removed parts in the reverse order of removal, and also fill in the coolant in the engine cooling system.

The article is missing:

• Tool photo
• Photo of parts and consumables

Source:  carpedia.club