Exhaust Manifold - Replacement & Warranty Extension
NO.: TSB-93-15-004DATE: December, 1993
MODEL: 1990 California 2.0L DOHC, Non-Turbo Galant
SUBJECT:
EXHAUST MANIFOLD WARRANTY EXTENSION
PURPOSE
In order to ensure continuing customer satisfaction, Mitsubishi Motor Sales of America Inc. (MMSA) has extended the exhaust manifold warranty on 1990 California emission specification 2.0L DOHC Non-Turbo Galant vehicles. The warranty is changed from 3 years/50,000 miles to 5 years/70,000 miles, whichever comes first. Customers with effected vehicles have been notified of this warranty extension. The purpose of this bulletin is to explain the conditions of the warranty, procedures to be taken if a customer elects to have their vehicle inspected for exhaust manifold cracks, and to provide exhaust manifold replacement instructions.
If a customer suspects an exhaust manifold problem, they can have their vehicle inspected at an authorized Mitsubishi Motors dealer. If cracks are found, the exhaust manifold will be replaced at no charge during the extended warranty period.
EXTENDED WARRANTY INFORMATION
The extended exhaust manifold warranty applies only to 1990 California emission specification 2.OL DOHC Non-Turbo Galant vehicles up to 5 years from date of sale, or date of first use, or 70,000 miles, whichever comes first. The extended exhaust manifold warranty does not apply to any other vehicles or emission specifications.
The warranty extension covers labor to inspect the condition of the exhaust manifold (if a customer elects to have their vehicle inspected) and/or replace the exhaust manifold if cracks are visible.
LABOR CLAIM INFORMATION
Submit all claims as type "W" on your Diamond Network System.
Exhaust Manifold Inspection
To be claimed only if a customer returns their vehicle and requests the service to be performed.
Nature Code: 99D
Cause Code: 100
Position Code: 153110
"00" Time Operation Number: 15311000
Time Allowance: 0.3 hrs.
Conditional Exhaust Manifold Replacement
This operation can only be performed if a crack is found in the exhaust manifold during the inspection procedure.
Note:
Do not claim an "Exhaust Manifold Inspection" labor operation when an exhaust manifold is replaced.
Nature Code: 99D
Cause Code: 100
Position Code: 153110
Operation number: 15311001
Time Allowance: 1.1 hrs.
Additional Time Allowance for DOHC engines: 153110B2
Time Allowance: 0.4 hrs.
Normal warranty parts storage requirements apply. You must retain all replaced manifolds and related parts for at least 60 days from the claim's paid monthly statement date unless you receive written notice to return the part to MMSA.
A sample exhaust manifold inspection warranty claim is shown.
A sample exhaust manifold replacement warranty claim is shown.
PARTS INFORMATION
No parts are allowed to be claimed for an exhaust manifold inspection procedure!
Note:
MD195540 exhaust manifold and MD194700 exhaust manifold inner cover, must be replaced as a set. The bolt hole pattern is different from the original manifold and not interchangeable. All other parts should be reused unless damaged.
EXHAUST MANIFOLD INSPECTION PROCEDURE
1. Disconnect the 02 sensor connector and set the wire aside.
2. Remove the 7 bolts from the exhaust manifold outer cover.
3. Remove the engine hanger bracket from the exhaust manifold by removing the 2 nuts and 1 bolt.
Note:
Removing the engine hanger bracket exposes more of the exhaust manifold for inspection.
4. Visually inspect the exhaust manifold for cracks.
Note:
The areas highlighted should be examined carefully.
5. If no cracks are visible, reinstall the parts in the reverse order.
Only if cracks are found, proceed with "EXHAUST MANIFOLD REPLACEMENT".
EXHAUST MANIFOLD REPLACEMENT
Note:
The exhaust manifold and the exhaust manifold inner cover, must be replaced as a set. The inner cover bolt hole pattern is different from the original manifold and not interchangeable. All other parts should be reused.
1. The exhaust manifold cover and engine hanger bracket should already be removed and the O2 sensor wire disconnected and set aside.
2. For clearance, if the vehicle is equipped with A/C, remove the left hand condenser fan. Remove the 3 bolts and unplug the connector.
3. Remove the exhaust pipe and gasket from the exhaust manifold by unscrewing the 3 self locking nuts and 1 bolt.
4. Remove the O2 sensor from the exhaust manifold using special tool MD998703.
5. Remove the exhaust manifold from the engine by removing the remaining nuts and washers from the cylinder head studs.
6. Verify the new exhaust manifold has an "S" mark on one of its runners as shown.
Note:
Manifolds which do not have an "S" mark should not be used for vehicles affected by this warranty extension.
Transfer the 3 studs on the exhaust outlet side to the new manifold (replace the studs only if damaged). Make certain the short threaded side is screwed into the manifold. Stud length after installation should be 24 mm +/- 1 mm.
7. Install the new exhaust manifold inner cover with 3 bolts. Torque the bolts to 9 to 11 ft.lbs.
8. Re-install the remaining parts in the reverse order of disassembly. Torque the fasteners to specifications listed in the 1989-1993 Galant service manual page 15-30.