Intake Manifold — Removal and Installation (4G61 DOHC, 16 Valves) (Mitsubishi Colt 4)

Intake manifold mounting elements
1 - ignition coil; 2 - manifold gasket; 3 - fuel line (injector frame); 4 - bracket; 5 - air duct; 6 - gasket; 7 - throttle body; 8 - gasket; 9 - air system element; 10 - Temperature sensor (related to the exhaust gas recirculation system); 11 - gasket; 12 - intake manifold support; 13 - intake manifold; 14 - ignition system unit.

Removal

Disconnect the ground cable from the battery.

Carefully relieve fuel pressure in the fuel system.

(The text of the article was obtained from the website: «MITSUBISHIMAN»)

Drain most of the coolant from the cooling system until the fluid is drained from the intake manifold passages.

Disconnect the upper radiator hose at the thermostat housing,

Disconnect the gas (accelerator) cable.

Remove all hoses.

Once labeled, remove each wire harness and cable that goes to the manifold and fuel injection system components.

Remove the fuel supply line, injectors and pressure regulator as a unit.

Remove the rubber grommets from the fuel line.

On this engine the ignition coil and transistor are secured, but we recommend removing them separately and storing them in a protected location.

Remove the intake manifold support, tie rod and transistor bracket.

Remove the intake manifold and gasket.

Remove the throttle body and gasket. The gasket must be replaced.

Remove the air intake pressure regulator bracket.

After unscrewing the bolts, remove the engine intake manifold.

Thoroughly clean the mating surfaces. Inspect the manifold and pressure regulator assembly for damage or cracks. Check each vacuum pipe and water passage for contamination. Use a ruler and feeler gauge to check the manifold and head surfaces for warpage.