MITSUBISHI ENDEAVOR 2004 Service Repair Manual

Fig. 3: Removing And Installing Intake Manifold Plenum

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Intake And Exhaust - Endeavor

INTAKE MANIFOLD REMOVAL AND INSTALLATION
2004 Mitsubishi Endeavor Limited 2004 ENGINE Intake And Exhaust - Endeavor

Fig. 4: Removin
g And Installin
g Intake Manifol
d

2004 Mitsubishi Endeavor Limited 2004 ENGINE Intake And Exhaust - Endeavor

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA
.
REMOVAL SERVICE POINT << A >> FUEL RAIL, INJECTOR AND FUEL DAMPER < UP TO DECEMBER 2003 >, FUEL RAIL AND INJECTOR <
FROM JANUARY 2004 > REMOVAL Remove the fuel rail with the injectors and fuel damper attached to it. INSTALLATION SERVICE POINTS >>A<< INTAKE MANIFOLD GASKET INSTALLATION Install the gasket with the protrusions in the position illustrated.
Fig. 5: Installing Gasket

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y of MITSUBISHI MOTOR SALES OF AMERICA
.
CAUTION: Care must be taken when removing the fuel rail not
to drop the injector.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Intake And Exhaust - Endeavor

>>B<< INTAKE MANIFOLD INSTALLATIONFig. 6: Identifying Intake Manifold

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1. Coat the intake manifold mounting studs with engine oil.
2. Tighten the intake manifold mounting nuts by the following procedure.
INTAKE MANIFOLD INSTALLATION
ORDER
MOUNTING NUTS
TIGHTENING TORQUE
1st
Right-bank nuts
6.5+/-1.5 N.m (58+/-13 in-lb)
2nd
Left-bank nuts
22+/-1 N.m (16+/-1 ft-lb)
3rd
Right-bank nuts
22+/-1 N.m (16+/-1 ft-lb)
4th
Left-bank nuts
22+/-1 N.m (16+/-1 ft-lb)
5th
Right-bank nuts
22+/-1 N.m
(16+/-1 ft-lb
)

2004 Mitsubishi Endeavor Limited 2004 ENGINE Intake And Exhaust - Endeavor

>>C<< FUEL HIG
H-PRESSURE HOSE INSTALLATION
1. When connecting the fuel high-pressure hose to the fuel rail, apply a small
amount of new engine oil to the O-ring and then insert the fuel high-pressure
hose, being careful not to damage the O-ring.
2. While turning the fuel high-pressure hose to the left and right, install it to the
fuel rail.
3. Check that the injector turns smoothly. If it does not turn smoothly, the O-ring
may be trapped. Remove the fuel high-pressure hose and then re-insert it into
the fuel rail and check again. INSPECTION Check the following points; replace the part if a problem is found. INTAKE MANIFOLD CHECK 1. Check for damage or cracking of any part.
2. Clogging of the negative pressure (vacuum) outlet port, or clogging of the
exhaust gas recirculation passages.
3. Using a straight edge and feeler gauge, check for distortion of the cylinder
head installation surface.
Standard value: 0.15 mm (0.006 inch) or less
Limit: 0.20 mm (0.008 inch)
CAUTION:
Be careful not to allow any engine oil to enter the
fuel rail. Be careful not to bend the fuel high-pressure
hose as it is made of plastics.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Intake And Exhaust - Endeavor

Fig. 7: Identifying Fuel High Pressure Hose

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EXHAUST MANIFOLD REMOVAL AND INSTALLATION < LEFT BANK >
2004 Mitsubishi Endeavor Limited 2004 ENGINE Intake And Exhaust - Endeavor

Fig. 8: Removing And Installing Exhaust Manifold (Left Bank)

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< RIGHT BANK >
2004 Mitsubishi Endeavor Limited 2004 ENGINE Intake And Exhaust - Endeavor

Fig. 9: Removing And Installing Exhaust Manifold (Right Bank)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Intake And Exhaust - Endeavor

Fig. 10: Identifying Special Tool

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2004 Mitsubishi Endeavor Limited 2004 ENGINE Intake And Exhaust - Endeavor