MITSUBISHI ENDEAVOR 2004 Service Repair Manual

Fig. 40: Removing/Installing Intake Manifold And Fuel Parts

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
< FROM JANUARY 2004 >
2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 41: Removing/Installing Intake Manifold And Fuel Parts (2 Of 2)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
INSTALLATION SERVICE POINTS
>>A<< INTAKE MANIFOLD INSTALLATION 1. Ti
ghten the nuts "R" to 6.5+
/-1.5 N.m
(57+
/-13 i
n-lb
).

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 42: Installing Intake Manifold

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Tighten the nuts "L" to the specified torque.
Tightening torque: 22+/-1 N.m (16+/-1 ft-lb)
3. Tighten the nuts "R" to the specified torque.
Tightening torque: 22+/-1 N.m (16+/-1 ft-lb)
4. Tighten the nuts "L" to the specified torque.
Tightening torque: 22+/-1 N.m (16+/-1 ft-lb)
5. Ti
ghten the nuts "R" to the s
pecified tor
que.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Tightening torque: 22+/-1 N.m (16+/-1 ft-lb)
>>B<< INJECTOR INSTALLATION 1. Apply clean engine oil to the O-ring.
2. Insert the injector into the fuel rail.
Fig. 43: Installing Injector

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3. Make sure the injector rotates smoothly. If not, remove the injector to check
the O-ring for damage, and replace the O-ring if necessary. Then reinsert the
injector and check that it rotates smoothly.
4. Confirm the
protrusion of in
jector is at center. I
f not
, rotate the in
jector fo
r
CAUTION: Use care not to let engine oil enter the fuel rail.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

protrusion to be center.
Fig. 44: Checking Protrusion Of Injector

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>>C<< INJECTOR AND FUEL RAIL INSTALLATION 1. Apply clean engine oil to the O-ring.
2. Insert the fuel pressure regulator into the fuel rail.
3. Make sure the regulator rotates smoothly. If not, remove the fuel pressure
regulator to check the O-ring for damage, and replace the O-ring if necessary.
Then reinsert the fuel pressure regulator and chec
k that it rotates smoothly.
CAUTION: Do not let engine oil enter the fuel rail.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

4. Tighten the two bolts to the specified torque.
Tightening torque: 9.0+/-1.0 N.m (80+/-9 in-lb) WATER PUMP & WATER HOSE REMOVAL AND INSTALLATION
2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 45: Removing/Installing Water Pump And Water Hose

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INSTALLATION SERVICE POINTS >>A<< O-RING AND WATER INLET PIPE INSTALLATION 1. Attach a new O-rin
g to each end of the water inlet
pipe.
CAUTION: Keep the O-ring free of oil or grease.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 46: Identifying Water Inlet Pipe And O Ring

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Wet the O-rin
g with water.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

3. Insert the front end of the pipe into the water pump. >>B<< THERMOSTAT HOUSING GASKET INSTALLATION Install the thermostat housing gasket so that the tab is positioned as shown in the
illustration.
Fig. 47: Installing Thermostat Housing Gasket

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>>C<< THERMOSTAT INSTALLATION 1. Check that the rubber ring is free from damage and seated correctly in the
thermostat flange.
2. Install the thermostat as shown in the illustration. The jiggle valve must be at
the to
p position.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 48: Installing Thermostat

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
>>D<< SEALANT APPLICATION TO ENGINE COOLANT TEMPERATURE SENSOR Apply 3M< SD >TM< /SD > AAD Part number 8731 or equivalent to the engine
coolant tem
perature sensor.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor