Mitsubishi Endeavor 2004-06

Intake Manifold

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  


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. Relieve the fuel pressure.
  2.  
  3. Partially drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     

  6.  


CAUTION
Wait at least 90 seconds after the negative battery cable is disconnected to prevent possible deployment of the air bag.



Air cleaner assembly
 
Throttle body
 
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 bank Heated Oxygen Sensor (HO2S) connector connections and clamps
 
Connector bracket
 
Evaporative emission (EVAP) purge solenoid connector
 
Purge hose
 
Purge hose connection
 
EVAP purge solenoid
 
Front intake manifold plenum stay
 
Exhaust Gas Recirculation (EGR) pipe A clamp
 
Power steering pressure hose clamp
 
Power steering pressure hose clamp bracket
 
Rear intake manifold plenum stay
 
EGR pipe B connection
 
Retaining bolts and intake manifold plenum
 
Intake manifold plenum gasket
 
EGR adapter and gasket
 
MDP sensor and O-ring
 
Ignition coil connector and coil
 
Injector connector
 
Engine mount stay
 
High pressure fuel hose and O-ring
 
Blow-by hose
 
Fuel rail and injectors. Also remove the damper assembly, if equipped.
 
Positive Crankcase Ventilation (PCV) hose
 
Right and left front upper timing belt cover
 
Water pump bracket
 
Intake manifold retainers, manifold and gasket. Thoroughly clean and dry the mating surfaces of the manifold and heads.
 



Click image to see an enlarged view

Fig. Exploded view of the intake manifold plenum-3.8L engine



Click image to see an enlarged view

Fig. Exploded view of the intake manifold-3.8L engine

To install:

  1. Install or connect the following:

    New intake manifold gasket. Make sure the gaskets are installed with the protrusions as shown in the illustration.
     


    Click image to see an enlarged view

    Fig. The intake manifold gaskets must be installed properly-3.8L engine

    Intake manifold
     

  2.  
  3. Install the intake manifold bolts and tighten as follows:
    1. 1st step: Right bank nuts to 58 inch lbs. (6.5 Nm).
    2.  
    3. 2nd step: Left bank nuts to 16 ft. lbs. (22 Nm).
    4.  
    5. 3rd step: Right bank nuts to 16 ft. lbs. (22 Nm).
    6.  
    7. 4th step: Left bank nuts to 16 ft. lbs. (22 Nm).
    8.  
    9. 5th step: Right bank nuts to 16 ft. lbs. (22 Nm).
    10.  



    Click image to see an enlarged view

    Fig. Left and right bank nut locations-3.8L engine



    Water pump bracket
     
    Right and left front upper timing belt cover
     
    PCV hose
     
    Fuel rail and injectors. Also remove the damper assembly, if equipped.
     
    Blow-by hose
     
    High pressure fuel hose with a new O-ring
     
    Engine mount stay
     
    Injector connectors
     
    Ignition coil connectors and coils
     
    MDP sensor and O-ring
     
    EGR adapter and gasket
     
    New intake manifold plenum gasket
     
    Intake manifold plenum. Tighten the plenum mounting bolts to 20 ft. lbs. (28 Nm).
     
    EGR pipe B connection
     
    Rear intake manifold plenum stay
     
    Power steering pressure hose clamp bracket
     
    Power steering pressure hose clamp
     
    EGR pipe A clamp
     
    Front intake manifold plenum stay
     
    EVAP purge solenoid, hose and connector
     
    Connector bracket
     
    Right bank HO2S clamps and connectors
     
    Control wiring harness and injector wiring harness combination connector
     
    CKP sensor connector
     
    KS connector
     
    MDP sensor connector
     
    Throttle body
     
    Air cleaner assembly
     
    Negative battery cable
     

  4.  
  5. Refill the radiator with coolant.
  6.  
  7. Check the system for fuel leaks.
  8.  
  9. Set all adjustments to specifications.
  10.  

  1. Before servicing the vehicle, refer to the Precautions Section.
    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.

  2.  
  3. Relieve the fuel pressure.
  4.  
  5. Partially drain the cooling system.
  6.  
  7. Remove or disconnect the following:
    CAUTION
    Wait at least 90 seconds after the negative battery cable is disconnected to prevent possible deployment of the air bag.



    Negative battery cable
     



    Air cleaner assembly
     
    Throttle body
     
    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 bank Heated Oxygen Sensor (HO 2 S) connector connections and clamps
     
    Connector bracket
     
    Evaporative emission (EVAP) purge solenoid connector
     
    Purge hose
     
    Purge hose connection
     
    EVAP purge solenoid
     
    Front intake manifold plenum stay
     
    Exhaust Gas Recirculation (EGR) pipe A clamp
     
    Power steering pressure hose clamp
     
    Power steering pressure hose clamp bracket
     
    Rear intake manifold plenum stay
     
    EGR pipe B connection
     
    Retaining bolts and intake manifold plenum
     
    Intake manifold plenum gasket
     
    EGR adapter and gasket
     
    MDP sensor and O-ring
     
    Ignition coil connector and coil
     
    Injector connector
     
    Engine mount stay
     
    High pressure fuel hose and O-ring
     
    Blow-by hose
     
    Fuel rail and injectors. Also remove the damper assembly, if equipped.
     
    Positive Crankcase Ventilation (PCV) hose
     
    Right and left front upper timing belt cover
     
    Water pump bracket
     
    Intake manifold retainers, manifold and gasket. Thoroughly clean and dry the mating surfaces of the manifold and heads.

    Click image to see an enlarged view

    Fig. Intake manifold plenum and related components



    Click image to see an enlarged view

    Fig. Intake manifold and related components

     

  8.  

To install:

  1. Install or connect the following:

    New intake manifold gasket. Make sure the gaskets are installed with the protrusions as shown in the illustration.

    Click image to see an enlarged view

    Fig. Intake manifold gasket positioning

     
    Intake manifold
     

  2.  
  3. Coat the intake manifold retaining studs with clean engine oil. Install the intake manifold bolts and tighten as follows:
    1. 1st step: Right bank nuts to 45-71 inch lbs. (5-8 Nm).
    2.  
    3. 2nd step: Left bank nuts to 15-17 ft. lbs. (21-23 Nm).
    4.  
    5. 3rd step: Right bank nuts to 15-17 ft. lbs. (21-23 Nm).
    6.  
    7. 4th step: Left bank nuts to 15-17 ft. lbs. (21-23 Nm).
    8.  
    9. 5th step: Right bank nuts to 15-17 ft. lbs. (21-23 Nm).

      Click image to see an enlarged view

      Fig. Intake manifold retaining nut location



      Water pump bracket
       
      Right and left front upper timing belt cover
       
      PCV hose
       
      Fuel rail and injectors. Also remove the damper assembly, if equipped.
       
      Blow-by hose
       
      High pressure fuel hose with a new O-ring
       
      Engine mount stay
       
      Injector connectors
       
      Ignition coil connectors and coils
       
      MDP sensor and O-ring
       
      EGR adapter and gasket
       
      New intake manifold plenum gasket
       
      Intake manifold plenum. Tighten the plenum mounting bolts to 20 ft. lbs. (28 Nm).
       
      EGR pipe B connection
       
      Rear intake manifold plenum stay
       
      Power steering pressure hose clamp bracket
       
      Power steering pressure hose clamp
       
      EGR pipe A clamp
       
      Front intake manifold plenum stay
       
      EVAP purge solenoid, hose and connector
       
      Connector bracket
       
      Right bank HO 2 S clamps and connectors
       
      Control wiring harness and injector wiring harness combination connector
       
      CKP sensor connector
       
      KS connector
       
      MDP sensor connector
       
      Throttle body
       
      Air cleaner assembly
       

    10.  

  4.  
  5. Refill the radiator with coolant.
  6.  
  7. 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.
  8.  
  9. Run the engine and check for fuel leaks, correct as required. Correct and adjust all fluid levels, as required.
  10.  

 
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