Mitsubishi Endeavor 2004-06

Engine

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NOTE
Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board computer systems and may require the computer to undergo a relearning process, once the negative battery cable is reconnected.

Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  


CAUTION
The fuel injection system remains under pressure after the engine has been OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Drain the engine oil.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Battery
     
    Hood, matchmark for reassembly
     
    Oil dipstick
     
    Engine undercover
     
    Starter
     
    Exhaust pipe from the exhaust manifolds
     
    Transfer case, if equipped with 4WD
     
    Transmission, if equipped with a manual transmission
     

  6.  
  7. If equipped with an automatic transmission and 2WD:
    1. Remove the inspection plate.
    2.  
    3. Matchmark the flexplate to the converter; remove the torque converter bolts and move the torque converter back as far as it will go.
    4.  
    5. Remove the lower bell housing bolts.
    6.  

  8.  
  9. Remove or disconnect the following:

    Air cleaner assembly, ducts and air intake hose
     
    Linkages and cables from the throttle body
     
    Fuel lines and plug the lines
     
    Air conditioning compressor, if equipped and position it aside. It is not necessary to remove the lines from the compressor.
     
    Radiator, shroud
     
    Cooling fan
     
    Heater hoses
     
    Accessory belts
     
    Power steering pump and wires from its brackets and position it to the side. Do not remove the hoses from the pump.
     
    Alternator and wires
     
    Ignition coil and power transistor assembly, if equipped
     
    MDP sensor connector
     
    EGR connector
     
    TP sensor connector
     
    IAC motor connector
     
    Magnetic clutch and refrigerant temperature switch connector
     
    EVAP Purge Solenoid
     
    ECT sensor and gauge connectors
     
    Front and injector wiring harness
     
    CMP sensor
     
    CKP sensor
     
    Distributor signal Generator
     
    Compactor connector
     
    Left and right heated O2 sensor
     
    Oil pressure switch connector
     
    Vacuum hoses
     

  10.  
  11. Attach an engine removal device to the engine support eyes on the engine.
  12.  
  13. If equipped with an automatic transmission, support the transmission with a floor jack. Remove the remaining bell housing bolts.
  14.  
  15. Remove the engine mount nuts and remove the engine from the vehicle.
  16.  

To install:

  1. Lower the engine into position and install the engine mount nuts and bolts. Tighten the nuts to 18-20 ft. lbs. (25-27 Nm), and the bolts to tighten to 33 ft. lbs. (44 Nm).
  2.  
  3. Install or connect the following:

    Bell housing bolts
     

  4.  
  5. Remove the engine removal device and the transmission support.
  6.  
  7. Install or connect the following:

    Transfer case, if equipped
     
    Manual transmission, if equipped
     
    Automatic transmission, if equipped align the torque converter and flexplate and the bolts.
     
    Inspection plate
     
    Starter motor
     
    Exhaust pipe to the exhaust manifolds using new gaskets
     
    Lower radiator hose
     
    Heater hoses
     
    Alternator and wires
     
    Power steering pump and brackets
     
    Air conditioning compressor
     
    Linkages and cables to the carburetor or throttle body
     
    Ignition coil and power transistor assembly, if equipped
     
    MDP sensor connector
     
    EGR connector
     
    TP sensor connector
     
    IAC motor connector
     
    Magnetic clutch and refrigerant temperature switch connector
     
    EVAP Purge Solenoid
     
    ECT sensor and gauge connectors
     
    Front and injector wiring harness
     
    CMP sensor
     
    CKP sensor
     
    Distributor signal Generator
     
    Compactor connector
     
    Left and right heated O2 sensor
     
    Oil pressure switch connector
     
    Vacuum hoses
     
    Air cleaner assembly, ducts and air intake hose
     
    Accessory belts
     
    Radiator, shroud and upper hose
     
    Cooling fan
     
    Battery
     
    Oil dipstick
     
    Hood
     

  8.  
  9. Refill the engine with the specified amount of oil.
  10.  
  11. Refill the radiator with coolant.
  12.  
  13. Check fuel system for leaks.
  14.  
  15. Check the automatic transmission fluid level, if equipped.
  16.  
  17. Recheck all engine adjustments.
  18.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
    CAUTION
    The fuel injection system remains under pressure after the engine has been OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  4.  
  5. Disconnect the negative battery cable. Remove the engine under cover.
  6.  
  7. Drain the engine oil. Drain the cooling system.
  8.  
  9. Matchmark and remove the engine hood. Remove the air cleaner.
  10.  
  11. Remove the Powertrain Control Module (PCM). Remove the battery. Remove the battery tray.
  12.  
  13. Remove the radiator grille. Remove the radiator assembly.
  14.  
  15. Remove the right side exhaust manifold.
  16.  
  17. Remove the transaxle.
  18.  
  19. Disconnect the EVAP solenoid connector. Disconnect the EVAP hose. Remove the EVAP solenoid.
  20.  
  21. Disconnect the vacuum hose connection. Disconnect the purge hose connection. Remove the front wiring harness and control wiring harness.
  22.  
  23. Remove the ground wire retaining screw. Remove the ground wire. Disconnect the fuel pipe retainer, and main pipe connector.
  24.  
  25. Disconnect the heater hose connection. Remove the reservoir assembly.
  26.  
  27. Remove the alternator drive belt. Remove the power steering pump belt.
  28.  
  29. Disconnect the air conditioning compressor electrical connector. Remove the air conditioning compressor from its mounting and position it to the side. Do not disconnect the refrigerant lines.
  30.  
  31. Disconnect the power steering pressure switch connector.
  32.  
  33. Remove the power steering pump and position it to the side. Do not disconnect the fluid lines.
  34.  
  35. Remove the power steering pressure hose clamp. Remove the power steering pressure hose clamp bracket.
  36.  
  37. Remove the engine mount stay. Remove the ground cable. Remove the locknuts.
  38.  
  39. Support the engine with a floor jack. Install the engine lifting fixture. Raise the engine slightly to take the tension of the engine mount.
  40.  
  41. Loosen the engine mount retaining nuts and bolts. Remove the engine mount.
  42.  
  43. After checking that all cables, hoses and wiring harness connectors are disconnected from the engine, remove the engine from the vehicle.
  44.  

To install:

  1. Lower the engine into position and install the engine mount nuts and bolts. Tighten the nuts to 18-20 ft. lbs. (25-27 Nm), and the bolts to tighten to 33 ft. lbs. (44 Nm).
  2.  
  3. Continue the installation in the reverse order of the removal procedure.
  4.  
  5. Be sure to check and adjust all fluid levels, as required.
  6.  
  7. Check fuel system for leaks.
  8.  
  9. On 2005-2006 vehicles, complete the vehicle initialization procedure.
    NOTE
    To complete the initialization procedure the following tools are needed. MB991958 scan tool, MB991824 VCI, MB991827 MUT III USB cable, MB991910 MUT III Main harness -A-.

  10.  
  11. Connect the scan tool to the data link connector. To prevent damage to the scan tool be sure that the ignition switch is in the LOCK position before connecting the scan tool.
  12.  
  13. Turn the ignition switch to the ON position.
  14.  
  15. Select -check mode- from the menu screen.
  16.  
  17. Select -erase memory- from the menu screen.
  18.  
  19. Initialize the learning value.
  20.  
  21. After initialization complete the idle learning procedure.
    NOTE
    This procedure must be performed when the PCM is replaced, or when the learning value is initialized, as the idling is not stabilized because the learning value in the MFI engine is not completed.

  22.  
  23. Start the engine. Allow the coolant temperature to reach 176 degrees or more.
  24.  
  25. Stop the engine and place the ignition switch in the LOCK position.
  26.  
  27. After ten seconds, restart the engine.
  28.  
  29. For ten minutes carry out the idling procedure below to confirm that the engine has normal idling.
    NOTE
    If the engine stalls during idling, check the throttle valve of the throttle body for dirt. Correct and perform the procedure again.



    Position the transaxle selector lever in the P range
     
    The engine fan is not to be operated
     
    The engine coolant temperature should be 176 degrees or more
     

  30.  
  31. Connect the negative battery cable. On 2005-06 models, rurn the ignition ON and then OFF , and keep it off for at least ten seconds.
  32.  

 
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