2004 MITSUBISHI ENDEAVOR service

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

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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

Fig. 13: Removing And Installing Ignition System

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
REQUIRED SPECIAL TOOLS:
MD998781: Flywheel Stopper
REMOVAL SERVICE POINT << A >> CAMSHAFT POSITION SENSING CYLINDER REMOVAL
2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

1. Using special tool MD998781, hold the drive plate or flywheel.
2. Loosen the camshaft position sensing cylinder bolt.
Fig. 14: Removing Camshaft Position Sensing Cylinder

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
INSTALLATION SERVICE POINT >>A<< CAMSHAFT POSITION SENSING CYLINDER INSTALLATION 1. Using special tool MD998781, hold the drive plate or flywheel.
2. Tighten the camshaft position sensing cylinder bolt to the specified torque.
Tightening torque: 22+/-4 N.m (16+/-3 ft-lb)
2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

MD998715: Pins MD998767: Tensioner Pulley Wrench MD998769: Crankshaft Spacer
REMOVAL SERVICE POINTS << A >> TIMING BELT REMOVAL 1. Mark the belt running direction for reinstallation.
2. Loosen the tensioner pulley bolt, and then remove
the timing belt.
CAUTION: Water or oil on the belt shortens its life drasticall
y, so
the removed timing belt, sprocket, and tensioner
must be kept free from oil and water. These parts
should not be washed or immersed in solvent.
Replace parts if contaminated. If there is oil or water
on any part, check the front case oil seal, camshaft
oil seal, and water pump for leaks.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 19: Removing Camshaft Sprocket

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
INSTALLATION SERVICE POINT >>A<< CAMSHAFT SPROCKET INSTALLATION 1. Fit the camshaft sprocket to the front end of the camshaft.
2. While holding the camshaft sprocket with special tools MB990767 and
MD998715, tighten the camshaft sprocket bolt.
Tightening torque: 88+/-10 N.m (65+/-7ft-lb)
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. 45: Removing/Installing Water Pump And Water Hose

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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. 50: Removing/Installing Exhaust Manifold

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
INSTALLATION SERVICE POINTS >>A<< EXHAUST MANIFOLD STAY, LEFT "B" INSTALLATION 1. Ti
ghten tem
poraril
y the left "B" of exhaust manifold sta
y to
gether with the

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor