Question about 2004 Mitsubishi Endeavor

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Engine light and fuel filler assembly

Just a heads up folks my o4 Endeavor with 92000 miles is completely rotted out where the fuel filler is behind the left rear wheel well.. Lousy design for protecting the filler tube allows road dirt and sand to accumulate with moisture untill the vents and filler tube are junk. Tried to fill tank and gas pours out all over the ground. Start complaints to Mitsubishi because I really think this is a design flaw and should be a recall. Oh by the way 200+ for part and approx 400 labor

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  • Anonymous Nov 04, 2008

    i have the same thing but they cant find the part for mine could be months.

  • Anonymous Nov 20, 2008

    I have the exact same problem and to make things worse the part is backordered from Mitsubishi! I've been waiting for 6 weeks for a replacement part so my mechanic can fix it! Urg. Any ideas where to get this part?

  • chemist88 Nov 28, 2008

    My girlfriend bought a 2005 this summer with 40,000 miles and she now has the same exact problem. Dealer wants $600 to fix it. Here in NY you cannot get your car inspected unless the check engine light is off. No choice but to get it fixed.

  • Anonymous Nov 28, 2008

    I have 2004 - same problem. Rotten gas mileage in the meantime of waiting for the part.

    My mechanic just got the part in. 2 hours for change and did not replace the flange that had about 3 pounds of gasoline soaked sand!!!

    I believe the back order from Mitsubishi is lifted, as just got part in this week. Don't know where ordered from exactly though.

  • Arthur Dalton Nov 30, 2008

    the part is in and the car is fixed 230 for the part and 280 in labor at a dealer broken bolts and rotted components what a mess ,.. start the complaints to mitsubishi

  • Anonymous Dec 06, 2008

    I ahve the same problem with my gas tank !!!This is terrible if i had known this i woudl not have bought it and they should fix it!

  • Anonymous Dec 07, 2008

    Exact same problem. Rotted fuel filler tube - broken bolts.

  • lutzd2 Dec 29, 2008

    I also have a 2004 with same problem part just came in today.

    On my second set of temp tags for plates waiting for the part.

    Hope I can fix it my self for $100 find problem and $300 for the part.

    Very disappointed in this flaw!

  • bsteen56 May 16, 2009

    The fuel filler tube on my 2004 Mitsubishi Endeavor has a rust hole in it.  I can only fill to about 2/3 full or gasoline leaks out during filling (and probably driving).  My dealer will charge about $500 to repair.  I have found others on the internet with the same complaint.

    Two years ago it was the infamous "air conditioner plugged drain line leaking water inside the vehicle" issue that cost nearly $2000 to repair.  Now it's a leaking fuel filler tube.  

    Oh, by the way.  My electric door locks just stopped working too.

  • Arthur Dalton Dec 21, 2009

    the problem is where the steel case mounts to the frame covering your pipe. It fills up with dirt and sand and moisture causing the fuel filler to rot out.. Small drain hole clog up and your trouble begin .. Either keep cleaned by flushing or wait for failure.

  • Arthur Dalton Jul 10, 2010

    Recieved a recall notice in the mail today 7/10/10 for the rotted out fuel filler neck. Now for the process of getting reimbursed for What I had to Pay 2 year s ago 100 for diagnosis and 500 for repairs

  • Arthur Dalton Jan 28, 2011

    Was finally recognized as a recall by Mitsubishi All owners should have recieved a form for the repair or refund if repair was done at your expense



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Reading all of the issues on the fuel filler and it spooked me because I live on the coast were the air is salty. I found nothing. It seems to be well protected behind a plastic guard and its covered with a steel case at the bend. I followed the tube to the gas tank and still found nothing.

Posted on Mar 14, 2009

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The fuel filter is in the fuel tank with the fuel pump

Posted on Mar 10, 2009

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I need to change the fuel filter, does anyone know where it is located?

Posted on Nov 07, 2008

  • bquifuma Nov 07, 2008

    I have a Mitsubishi Endeavor 2004, I want to know where is the Fuel Filter located. Thank you


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My digital gas gage reads full all the time I have to go by my miles and sometimes that don't work and I run out of do I fix my problem

This is a common problem and to correct this problem will require the replacement of the fuel sending unit. The fuel sending unit is inside the fuel tank and has the fuel pump mounted in it. This requires the removal of the gas tank and then the fuel sending unit can be removed from the tank.

REMOVAL AND INSTALLATION Fig. 1: Fuel pump unit 8470h037.gif
  1. Disconnect the negative battery cable.
  2. Relieve fuel system pressure.
  3. Remove fuel filler cap to release fuel tank vapors. Leave cap off until repairs are completed. Gasoline fuel vapors are extremely flammable. Ensure that fuel is stored in a container that can be properly sealed. Never store fuel in an open container. Store container in a safe place away from heat.
  4. Remove fuel tank by performing the following:
    1. Step 1: Drain fuel from the tank into an approved container for storage.
    2. Step 2: Raise and safely support the vehicle.
    3. Step 3: Remove rear stabilizer bar at links, pivot bar downward.
    4. Step 4: Remove hoses and pipes from tank unit.
    5. Step 5: Remove hoses at tank from filler and vent pipe.
    6. Step 6: Disconnect tank unit harness from rear body harness.
    7. Step 7: Support fuel tank and disconnect 2 fuel tank retaining straps.
    8. Step 8: Remove tank from vehicle.
  5. Remove sending unit, gasket and pump assembly by turning cam lock ring counterclockwise. Lift assembly from fuel tank and remove fuel pump from fuel tank sending unit.
  6. Pull fuel pump up into attaching hose while pulling outward away from bottom support. Take care to prevent damage to rubber insulator and strainer during removal. After pump assembly is clear of bottom support, pull pump assembly out of rubber connector for removal. To install:
  7. Push fuel pump assembly into attaching hose.
  8. Install fuel tank sending unit and pump assembly into tank assembly. Use new O-ring seal during reassembly.
  9. Install cam lock over assembly and lock by turning clockwise.
  10. Support tank and position in vehicle. Install tank straps and secure with retaining bolts. Tighten to 25 ft. lbs. (33 Nm).
  11. Connect tank unit harness to body harness.
  12. Connect hoses to filler and vent pipes. Tighten clamps.
  13. Connect hoses and pipes to tank unit.
  14. Connect rear stabilizer bar to links. Tighten bolts to 42 ft. lbs. (58 Nm).
  15. Lower vehicle.
  16. Refill tank and install filler cap.
  17. Connect negative battery cable.
  18. Start engine and check for leaks.

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2004 endeavor stalls and won't start. If I wait a while I can start and drive it again. Doesn't seem to have any pattern on when it will stall again.

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Nov 08, 2009 | 2004 Mitsubishi Endeavor

1 Answer



  1. Disconnect the negative battery cable.
  2. Drain all the fuel from the tank.
  3. Install and tighten the drain plug. Tighten Tighten the drain plug to 20 N.m (14 lb ft.) .
  4. Remove the fuel tank.
  5. Remove the retaining screws from the fuel tank.
  6. Remove the fuel pump assembly from the fuel tank.
    1. Cover the fuel pump opening in order to prevent dust, dirt, or debris from entering the fuel tank.

    1. Install the fuel pump assembly. Tighten Tighten the fuel pump assembly mounting bolts to 3 N.m (27 lb ft.) .
    2. Install the fuel pump assembly retaining screws.
    3. Install the fuel tank assembly.
    4. Fill the tank with fuel.
    5. Tighten the fuel filler cap.
      1. Connect the negative battery cable.

      CAUTION: When repair to the fuel system has been completed, start engine and check the fuel system for loose connection or leakage. For the fuel system diagnosis, see Computers and Control Systems/System Diagnosis.

      1. Disconnect battery ground cable.
      2. Loosen fuel filler cap.
      3. Drain fuel. Tighten drain plug to the specified torque after draining fuel. Torque: 20 N.m (14 lb ft) - M8
      4. Remove fuel tank assembly (1).
      5. Remove fuel pump (FP) assembly (2) fixing screws and remove the FP assembly.
      NOTE: After removing FP, cover fuel tank to prevent any dust entering.
      1. Install FP assembly (2).
      2. Install fuel tank assembly (1).
      3. Fill the tank with fuel and tighten fuel filler cap.
      4. Connect battery ground cable.

Oct 18, 2009 | 2001 Isuzu Trooper

1 Answer

Check engine light is on for emission evaporator failure-large

P0455 - EVAP Control System Leak Detected (No Purge Flow or Large Leak) The PCM monitors the complete EVAP control system for no purge flow, the presence of a large fuel vapor leak or multiple small fuel vapor leaks. The system failure occurs when no purge flow (attributed to fuel vapor blockages or restrictions), a large fuel vapor leak or multiple fuel vapor leaks are detected by the EVAP running loss monitor test with the engine running (but not at idle).
  • After-market EVAP hardware (such as fuel filler cap) non-conforming to required specifications
  • Disconnected or cracked fuel EVAP canister tube, EVAP canister purge outlet tube or EVAP return tube
  • EVAP canister purge valve stuck closed
  • Damaged EVAP canister
  • Damaged or missing fuel filler cap
  • Insufficient fuel filler cap installation
  • Loose fuel vapor hose/tube connections to EVAP system components
  • Blockages or restrictions in fuel vapor hoses/tubes (items also listed under disconnections or cracks)
  • Fuel vapor control valve tube assembly or fuel vapor vent valve assembly blocked
  • Canister vent (CV) solenoid stuck open
  • Mechanically inoperative fuel tank pressure (FTP) sensor
Check for audible vacuum noise or significant fuel odor in the engine compartment or near the EVAP canister and fuel tank. ----------------------------------------------------------------------------- HX43 DTC P0457: CHECK FOR MISSING OR LEAKING FUEL FILLER CAP
  • Check for missing fuel filler cap.
  • Check for loose fuel filler cap.
  • Check for possible cross-thread fuel filler cap condition.
Is a fault present concerning the proper installation of the fuel filler cap? Yes No REPLACE cross-threaded or damaged fuel filler cap. RECONNECT and TIGHTEN the fuel filler cap only one eighth turn so that the cap initially clicks by sound or touch. CLEAR Continuous Memory DTCs. COMPLETE an Evaporative Emission Running Loss Monitor Repair Verification Drive Cycle (refer to Section 2 , Drive Cycles). RERUN Quick Test . If DTC P0455 or P0457 is present, Go to HX44 . CLEAR Continuous Memory DTCs. COMPLETE an Evaporative Emission Running Loss Monitor Repair Verification Drive Cycle (refer to Section 2 , Drive Cycles). RERUN Quick Test .

For DTC P0455 still present: Go to HX44 .

Otherwise, INFORM the vehicle owner that it is important and necessary to immediately install the fuel filler cap after every refueling event. HX44 DTC P0455: VISUAL INSPECTION FOR SUBSTANTIAL EVAPORATIVE EMISSION SYSTEM LEAKS
  • Check for missing fuel filler cap. If the cap is loose DO NOT DISTURB EVAP system.
  • Verify that both the input port vacuum hose and EVAP return tube are attached to the EVAP canister purge valve. Note: If the EVAP canister-CV solenoid assembly is not accessible during this pinpoint test step, GO to Evaporative Emissions, Section 303-13 in the Workshop Manual for removal and installation instructions.
  • Verify that the CV solenoid is properly seated on the EVAP canister (if possible).
  • Visually inspect for disconnected or cracked fuel vapor hoses/tubes between the intake manifold, the EVAP canister purge valve, the EVAP canister, the fuel vapor vent valve assembly and if applicable the fuel vapor control valve tube assembly.
  • Check for damage to the fuel filler pipe and the fuel tank.
Is a fault indicated? Yes No CONNECT or REPLACE fuel vapor hoses/tubes as required. REPLACE damaged EVAP system components (fuel filler pipe, fuel vapor vent valve assembly, fuel vapor control valve tube assembly, EVAP canister purge valve, FTP sensor and EVAP canister-CV solenoid assembly) as necessary. REFER to Evaporative Emissions, Section 303-13 in the Workshop Manual for removal and installation instructions. GO to HX45 . GO to HX45 . HX45 DTC P1443 and P0455: CHECK FOR EVAPORATIVE EMISSION SYSTEM LEAKS
    Note: When checking for leaks or blockages in the EVAP system, energize (close) the canister vent (CV) solenoid through the scan tool for a maximum of nine minutes per pinpoint test step. Then de-energize the CV solenoid prior to performing the subsequent pinpoint test step. This is done to assure proper closing of the solenoid.
  • Disconnect and plug the EVAP return tube (EVAP canister purge valve to intake manifold) at the intake manifold vacuum source.
  • Connect scan tool.
  • Key on, engine off.
  • Access VPWR PID. If the voltage is not 12 volts or greater, GO to HX61 .
  • Locate evaporative test port [marked EVAPORATIVE SERVICE PORT DO NOT USE UNREGULATED PRESSURE ABOVE 6.89 kPa (1 PSI)] near EVAP canister purge valve or EVAP canister.
  • If vehicle is not equipped with the evaporative test port, GO to HX50 .
  • Install the Rotunda Evaporative Emission System Leak Tester 310-F007 (134-00056) or equivalent at the evaporative test port.
  • Close CV solenoid by accessing Output Test Mode on the scan tool.
  • Select ALL OFF mode and push START button.
  • Regulate the nitrogen or argon gas pressure on the tester to 3.48 kPa (14 in-H 2 O).
  • Follow the instructions that come with the EVAP System Leak Tester and pressurize the EVAP system.
  • Perform the EVAP system leak test.
Does the pressure on the EVAP system stay above 1.99 kPa (8 in-H 2 O) and pass the leak test? Yes No GO to HX46 . REMOVE the EVAP System Leak Tester from the evaporative test port and REINSTALL the test port cap. GO to HX50 .

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1 Answer

2000 ford ranger

It isn’t a check engine light problem. Unless moisture has been able to get into your fuel tank. You can purchase that hose from most auto parts stores.

Jul 09, 2008 | 2000 Ford Ranger SuperCab

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