Mitsubishi Endeavor 2004-06

Exhaust Manifold

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Removal & Installation



Left Side Exhaust Manifold
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Engine under cover
     
    Air duct
     
    Left Heated Oxygen Sensor (HO2S) connectors and sensors
     
    Engine oil dipstick, guide and O-ring
     
    Heat shield
     
    Front exhaust pipe from the manifold. Remove and discard the gasket.
     
    Exhaust manifold stay (left B)
     
    Left side exhaust manifold and gasket
     
    Exhaust manifold stay (left A)
     

  4.  
  5. Clean the gasket mounting surfaces. Inspect the manifolds for cracks, flatness and/or damage.
  6.  

To install:

  1. Install or connect the following:

    Exhaust manifold stay (left A)
     
    New gasket and left side exhaust manifold. Torque the nuts to 30-36 ft. lbs. (39-49 Nm).
     
    Exhaust manifold stay (left B)
     
    Exhaust pipe to the manifold with a new gasket. Torque the bolts to 31-43 ft. lbs. (40-58 Nm).
     
    Left side heat shield
     
    Oil dipstick, guide and new O-ring
     
    Left HO2S and connectors
     
    Air duct
     
    Under cover
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for exhaust leaks.
  4.  


    Click image to see an enlarged view

    Fig. Exploded view of the left bank exhaust manifold-3.8L engine


  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Engine under cover
     
    Air duct
     
    Left Heated Oxygen Sensor (HO2S) connectors and sensors
     
    Engine oil dipstick, guide and O-ring
     
    Heat shield
     
    Front exhaust pipe from the manifold. Remove and discard the gasket.
     
    Exhaust manifold stay (left B)
     
    Left side exhaust manifold and gasket
     
    Exhaust manifold stay (left A)
     

  4.  
  5. Clean the gasket mounting surfaces. Inspect the manifolds for cracks, flatness and/or damage.
  6.  

To install:

  1. Install or connect the following:

    Exhaust manifold stay (left A)
     
    New gasket and left side exhaust manifold. Torque the nuts to specification.
     
    Exhaust manifold stay (left B)
     
    Exhaust pipe to the manifold with a new gasket. Torque the bolts to 31-43 ft. lbs. (40-58 Nm).
     
    Left side heat shield
     
    Oil dipstick, guide and new O-ring
     
    Left HO2S and connectors
     
    Air duct
     
    Under cover
     

  2.  
  3. Connect the negative battery cable. On 2005-2006 vehicles, turn the ignition ON and then OFF , and keep it off for at least ten seconds.
  4.  
  5. Start the engine and check for exhaust leaks.

    Click image to see an enlarged view

    Fig. Left bank exhaust manifold and related components

  6.  

Right Side
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the transfer case fluid and the engine coolant.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner assembly
     
    Battery and battery tray
     
    Under cover
     
    Front exhaust pipe from the right exhaust manifold
     
    Propeller shaft, if AWD
     
    Manifold Differential Pressure (MDP) sensor connector
     
    Knock Sensor (KS) connector
     
    Crankshaft Position (CKP) sensor connector
     
    Control wiring harness and injector wiring harness combination connector
     
    Right Heated Oxygen Sensor (HO2S) connectors
     
    Connector bracket
     
    Right HO2S sensor connector clamps and sensors
     
    Exhaust Gas Recirculation (EGR) pipe A connection
     
    Water hoses
     
    EGR pipe A and gasket
     
    Exhaust manifold stay (right B)
     
    Steering gear and linkage protector
     
    Front floor backbone brace
     
    Front heat protector panel
     
    Transfer extension housing and O-ring, if AWD
     
    Lower and upper heat shields
     
    Power steering return pipe clamp connecting bolt and nut, if AWD
     
    Right side exhaust manifold and gasket
     

  6.  
  7. Clean the gasket mounting surfaces. Inspect the manifolds for cracks, flatness and/or damage.
  8.  

To install:

  1. Install or connect the following:

    New gasket and right side exhaust manifold. Torque the nuts to 30-36 ft. lbs. (39-49 Nm).
     
    Power steering return pipe clamp connecting bolt and nut, if AWD
     
    Lower and upper heat shields
     
    Transfer extension housing and O-ring, if AWD
     
    Front heat protector panel
     
    Front floor backbone brace
     
    Steering gear and linkage protector
     
    Exhaust manifold stay (right B)
     
    EGR pipe A and gasket
     
    Water hoses
     
    EGR pipe A connection
     
    Right HO2S sensors and connector clamps
     
    Connector bracket
     
    Right HO2S connectors
     
    Control wiring harness and injector wiring harness combination connector
     
    CKP sensor connector
     
    Knock Sensor (KS) connector
     
    Manifold Differential Pressure (MDP) sensor connector
     
    Propeller shaft, if AWD
     
    Front exhaust pipe to the exhaust manifold
     
    Under cover
     
    Battery and battery tray
     
    Air cleaner assembly
     
    Negative battery cable
     

  2.  
  3. Fill the transfer case with fluid. Fill the engine cooling system.
  4.  
  5. Start the engine and check for exhaust leaks.
  6.  


    Click image to see an enlarged view

    Fig. Exploded view of the right exhaust manifold-3.8L engine


  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the transfer case fluid and the engine coolant.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner assembly
     
    Battery and battery tray
     
    Under cover
     
    Front exhaust pipe from the right exhaust manifold
     
    Propeller shaft, if AWD
     
    Manifold Differential Pressure (MDP) sensor connector
     
    Knock Sensor (KS) connector
     
    Crankshaft Position (CKP) sensor connector
     
    Control wiring harness and injector wiring harness combination connector
     
    Right Heated Oxygen Sensor (HO2S) connectors
     
    Connector bracket
     
    Right HO2S sensor connector clamps and sensors
     
    Exhaust Gas Recirculation (EGR) pipe A connection
     
    Water hoses
     
    EGR pipe A and gasket
     
    Exhaust manifold stay (right B)
     
    Steering gear and linkage protector
     
    Front floor backbone brace
     
    Front heat protector panel
     
    Transfer extension housing and O-ring, if AWD
     
    Lower and upper heat shields
     
    Power steering return pipe clamp connecting bolt and nut, if AWD
     
    Right side exhaust manifold and gasket
     

  6.  
  7. Clean the gasket mounting surfaces. Inspect the manifolds for cracks, flatness and/or damage.
  8.  

To install:

  1. Install or connect the following:

    New gasket and right side exhaust manifold. Torque the nuts to specification.
     
    Power steering return pipe clamp connecting bolt and nut, if AWD
     
    Lower and upper heat shields
     
    Transfer extension housing and O-ring, if AWD
     
    Front heat protector panel
     
    Front floor backbone brace
     
    Steering gear and linkage protector
     
    Exhaust manifold stay (right B)
     
    EGR pipe A and gasket
     
    Water hoses
     
    EGR pipe A connection
     
    Right HO2S sensors and connector clamps
     
    Connector bracket
     
    Right HO2S connectors
     
    Control wiring harness and injector wiring harness combination connector
     
    CKP sensor connector
     
    Knock Sensor (KS) connector
     
    Manifold Differential Pressure (MDP) sensor connector
     
    Propeller shaft, if AWD
     
    Front exhaust pipe to the exhaust manifold
     
    Under cover
     
    Battery and battery tray
     
    Air cleaner assembly
     

  2.  
  3. Connect the negative battery cable. On 2005-2006 vehicles, turn the ignition ON and then OFF , and keep it off for at least ten seconds.
  4.  
  5. Fill the transfer case with fluid. Fill the engine cooling system.
  6.  
  7. Start the engine and check for exhaust leaks.

    Click image to see an enlarged view

    Fig. Right bank exhaust manifold and related components

  8.  

 
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