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The 3.8L V6 suffers from a variable intake runner that after around 100,000 miles can create some very serious problems. Unfortunately, a replacement unit costs around $700 in parts alone. They can be rebuilt using a new Kia Sorento Manifold and a however, or if the only problem you're experiencing is a vacuum leak, a new o-ring in the front can fix that issue.
However, a somewhat popular mod when faced with a leaking or rattling butterfly rod in the variable intake runner is to delete the entire assembly. This will give you peace of mind knowing that there are now no more bushings, screws, or butterfly valves in the surgetank that can fall into the combustion chambers. However, in our experience, deleting this feature will have cause a large torque reduction of anywhere between 10-20% (depending on your gearing). So while we don't recommend deleting your butterfly valves, we do understand it and that's why we offer this kit.
This aluminum disc is the perfect size to block off the entry port for the butterfly rod after it has been removed from the surge tank. We include 2 discs in case you mess up ;-)
Note - Although Gen2 DOHC engines also suffer from the dreaded varible intake we do not know if these discs are the correct size for that application.
- High Temp RTV recommended
- Forum Post
- Video - "Smoke testing Intake & Exhaust systems for air leaks - Gen3 Mitsubishi Montero"
- Video - "Changing the intake manifold gasket on a Mitsubishi Montero."
- Video - "2003 Mitsubishi Montero Surge Tank Butterfly Valves Bushings Replacement"
- Video - "Montero Butterfly Valve removal AKA the piston eater."
- Video - "Gen 3 Mitsubishi Montero 3.8l lower intake repair 6g75 2003-2006"