Intake MITSUBISHI ENDEAVOR 2004 Service Owner's Manual

SYMPTOM PROCEDURES INSPECTION PROCEDURE 1: EXHAUST LEAKAGE DIAGNOSIS 1.STEP 1. Start the engine. Have an assistant stay in the driver's seat. Raise
the vehicle on a hoist. Have the assistant rev the en
gine while searchin
g for
exhaust leaks.
Q: Is the exhaust leaking?
YES : Go to Step 2.
NO : The procedure is complete.
2.STEP 2. Check the gasket for cracks, damage.
Q: Is the gasket damaged?
YES : Replace the gasket, then go Step 1 .
NO : Go to Step 3.
3.STEP 3. Check for loosening in each coupling section.
Q: Is there any loosening in each section?
YES : Tighten, then go to Step 1 .
NO : There is no action to be taken.
INSPECTION PROCEDURE 2: ABNORMAL NOISE DIAGNOSIS 1.STEP 1. Start the engine. Have an assistant stay in the drivers seat. Raise
the vehicle on a hoist. Have the assistant rev the en
gine while searchin
g for
exhaust leaks.
Q: Is any abnormal noise generated?
YES : Go to Step 2.
NO : The
procedure is com
plete.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Intake And Exhaust - Endeavor

2.STEP 2. Check for missing parts in the muffler. Tap the muffler lightly to
check for loose baffles, etc.
Q: Are there any missing parts in the muffler?
YES : Replace, then go to Step 1 .
NO : Go to Step 3.
3.STEP 3. Check the hanger for cracks.
Q: Is the hanger cracked?
YES : Replace, then go to Step 1 .
NO : Go to Step 4.
4.STEP 4. Check for interference of the pipes and muffler with the body.
Q: Are the pipes and muffler interfering with the body?
YES : Repair, then go to Step 1 .
NO : Go to Step 5.
5.STEP 5. Check the heat protectors.
Q: Are any heat protectors loose or damaged?
YES : Tighten or replace, then go to Step 1 .
NO : Go to Step 6.
6.STEP 6. Check the pipes and muffler for damage.
Q: Are the pipes and muffler damaged?
YES : Replace, then go to Step 1 .
NO : There is no action to be taken. SPECIAL TOOL
2004 Mitsubishi Endeavor Limited 2004 ENGINE Intake And Exhaust - Endeavor

Fig. 1: Identifying Special Tool

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
AIR CLEANER REMOVAL AND INSTALLATION
2004 Mitsubishi Endeavor Limited 2004 ENGINE Intake And Exhaust - Endeavor

Fig. 2: Removing And Installing Air Cleaner

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
INTAKE MANIFOLD PLENUM REMOVAL AND INSTALLATION
2004 Mitsubishi Endeavor Limited 2004 ENGINE Intake And Exhaust - Endeavor

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

Courtes
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

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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