MITSUBISHI ENDEAVOR 2004 Service Repair Manual

Fig. 3: Removing/Installing Generator And Drive Belt Component

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REQUIRED SPECIAL TOOL:
MD998781: Flywheel Stopper
REMOVAL SERVICE POINT << A >> CRANKSHAFT BOLT LOOSENING
2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

1. Using special tool MD998781, hold the drive plate or flywheel.
2. Remove the crankshaft bolt.
Fig. 4: Removing Crankshaft Bolt Using Special Tool

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INSTALLATION SERVICE POINT >>A<< CRANKSHAFT BOLT TIGHTENING 1. Usin
g special tool MD998781, hold the drive
plate or fl
ywheel.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 5: Holding The Drive Plate Or Flywheel Using Special Tool MD998781

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Clean the bolt hole in crankshaft bolt, damper pulley seating surface and the
washer.
3. Degrease the cleaned seating surface of the damper pulley.
4. Install the damper pulley.
5. Apply a minimum amount engine oil to the thread and lower flange of the
crankshaft bolt.
6. Install the washer to the crankshaft bolt with its inside chamfered side toward
the bolt head.
7. Tighten the crankshaft bolt to the specified torque.
Tightening torque: 185+/-5 N.m (137+/-3 ft-lb)

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 6: Tightening The Crankshaft Bolt To The Specified Torque

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INTAKE MANIFOLD PLENUM AND THROTTLE BODY ASSEMBLY REMOVAL AND INSTALLATION
2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 7: Removing/Installing Intake Manifold Plenum And Throttle Body Assembly

Cou
rtesy
of MIT
SU
BI
SHI M
OTOR SALE
S OF AMERI
CA.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

INSTALLATION SERVICE POINT>>A<< BOOST SENSOR INSTALLATION
>>B<< THROTTLE BODY GASKET INSTALLATION Install the throttle body gasket so that the tab is positioned as shown in the
illustration.
Fig. 8: Installing The Throttle Body Gasket

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CAUTION:
Do not strike or drop to the sensor. Never use a sensor that has been dropped.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

>>C<< EXHAUST GAS RECIRCULATION VALVE GASKET INSTALLATION Install the exhaust gas recirculation valve gasket so that the tab is positioned as
shown in the illustration.
Fig. 9: Installing The Exhaust Gas Recirculation Valve Gasket

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>>D<< EXHAUST GAS RECIRCULATION PIPE GASKET INSTALLATION Install the exhaust gas recirculation pipe gasket so that the tab is positioned as
shown in the illustration.
2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 10: Installing The Exhaust Gas Recirculation Pipe Gasket

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>>E<< EXHAUST GAS RECIRCULATION PIPE GASKET INSTALLATION Install the exhaust gas recirculation pipe gasket so that the tab is positioned as
shown in the illustration.
2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 11: Installing The Exhaust Gas Recirculation Pipe Gasket

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>>F<< EXHAUST GAS RECIRCULATION PIPE (EXHAUST SIDE) INSTALLATION 1. Tighten temporarily the flare nut of exhaust gas recirculation pipe and the nut
shown in the illustration.
2. Tighten each the flare nuts of exhaust gas recirculation pipe and the nut shown
in the illustration, to the specified torque.
Tightening torque:
59+/-10 N.m (44+/-7 ft-lb) < FLARE NUT >
11+/-1 N.m (95+/-9 in-lb) < NUT >
CAUTION: Use care to prevent deforming the bellows of the
exhaust gas recirculation pipe.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

3. Tighten the bolt shown in the illustration, to the specified torque:
Tightening torque: 19+/-3 N.m (14+/-2 ft-lb)
Fig. 12: Tightening Torque Specification

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IGNITION SYSTEM REMOVAL AND INSTALLATION
2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor