Exhaust manifold — removal and installation (4G61 DOHC, 16 valves) (Mitsubishi Colt 4)

Exhaust manifold mounting elements
1 - heat shield; 2 - oxygen sensor; 3 - radiator; 4 - collector heat shield; 3 - lifting bracket; 6 - exhaust manifold; 7 - air intake hose; 8 - gasket; 9 - air hose; 10 - lifting bracket; 11, 12 - cooling system hose.

Removal

CAUTION: This work must be performed only on a cold engine.

Disconnect the ground cable from the battery.

Drain the coolant from the cooling system.

After disconnecting the upper and lower coolant hoses from the engine, remove the radiator with the hoses attached to it. Do not remove the electric fan from the radiator shroud.

Using a special collet, carefully remove the oxygen sensor (lambda probe).

Place the sensor in a protected location.

Disconnect the air intake hose from the turbocharger (if equipped).

Once marked, remove the small vacuum hoses from the turbocharger.

Disconnect the air hose from the turbocharger (if equipped).

Remove the heat shield from the top of the manifold.

Remove the heat shield from the front and side surfaces of the turbocharger.

After unscrewing the two nuts securing the engine lift bracket, remove this bracket.

Disconnect the eyebolt above the turbocharger. Remove and discard the two washers (gaskets) from this connection.

After marking, remove the coolant hose from the turbocharger. Carefully unscrew and remove the nipple for the water pipe (12) and the turbocharger. When removing the nipple, do not break the fitting.

After removing the exhaust pipe bracket bolt, remove the self-locking nuts securing the exhaust pipe to the turbocharger (if equipped).

Carefully separate the pipe from the turbocharger and remove the gasket from the connection.

Loosen the nuts and bolts securing the exhaust manifold.

Remove the manifold, its gasket and sealing ring, and hang the turbocharger using a piece of wire or rope.

Carefully inspect the manifold for cracks and damage. Using a ruler and a set of feeler gauges, check the cylinder head surface for warpage. The maximum permissible warpage is 0.3 mm.