2004 MITSUBISHI ENDEAVOR service

MD998442: Air Bleed Wire MD998443: Lash Adjuster Holder MD998713: Camshaft Oil Seal Installer
REMOVAL SERVICE POINT << A >> ROCKER ARMS AND SHAFT REMOVAL Set special tool MD998443 to prevent the lash adjuster from coming free and
falling to the floor.
Fig. 54: Setting Special Tool MD998443 To Prevent The Lash Adjuster From
CAUTION: If the lash adjuster is re-used, clean the lash ad
juster.
(Refer to LASH ADJUSTER INSPECTION
.)

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Coming Free

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INSTALLATION SERVICE POINTS >>A<< CAMSHAFT INSTALLATION 1. Apply engine oil to the camshaft journals and cams and then install the
camshafts.
Fig. 55: Identifying Left And Right Camshaft

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CAUTION: Use care to prevent confusion of the right and left
bank camshafts.
NOTE: The camshaft with a longer overall length is for the left
bank.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

REMOVAL SERVICE POINTS << A >> CYLINDER HEAD BOLT REMOVAL Use special tool MD998051 to loosen the cylinder head bolt.
Fig. 73: Removing Cylinder Head Bolt

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< > RETAINER LOCK REMOVAL 1. Using special tool MD998735 or MD998772, compress the spring.
2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 75: Removing Spring Using Special Tool MD998772

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INSTALLATION SERVICE POINTS >>A<< VALVE STEM SEAL INSTALLATION 1. Install the valve spring seat. NOTE: Tag removed valves, springs and other components, noting
their cylinder numbers and locations to facilitate
reassembly. Store these components safely.
CAUTION:
Valve stem seals for intake valves and for
exhaust valves are different. Be sure to
install the correct ones.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

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.
2. Back off the bolts once and tighten them again to the specified torque in step 1.
INSPECTION CYLINDER HEAD 1. Check the cylinder head gasket surface for flatness by using a straightedge in
the directions of A through G shown in the illustration.
Standard value: 0.03 mm (0.0012 inch)
Limit: 0.2 mm (0.007 inch)
2. If the service limit is exceeded, correct to meet the specification.
Grinding limit: *0.2 mm (0.007 inch)
3. *If the service limit is exceeded, correct to meet the specification.
Cylinder head height (specification when new): 120 mm (4.7 inches)
2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 83: Checking Valve Face And Margin

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2. If the margin exceeds the service minimum limit, replace the valve.
Standard value:
< Intake > 1.0 mm (0.04 inch)
< Exhaust > 1.2 mm (0.05 inch)
Minimum limit:
< Intake > 0.5 mm (0.02 inch)
< Exhaust > 0.7 mm (0.03 inch)
3. Measure the valve's total length. If the measurement is less than specified,
replace the valve.
Standard value:

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

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.
REQUIRED SPECIAL TOOL
MD998054: Oil Pressure Switch Socket Wrench MD998717: Crankshaft Front Oil Seal Installer
REMOVAL SERVICE POINT << A >> OIL PAN, LOWER REMOVAL 1. Remove the lower oil pan mounting bolts.
2. Remove the lower oil pan by tapping on its side with a plastic hammer (mallet)
through a wooden plank held against it. < B > OIL PAN, UPPER REMOVAL 1. Remove the long bolts "A" shown in the illustration first.
CAUTION: Do not use a scraper or special tool to remove
the oil pan.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

<< C >> OUTER ROTOR/INNER ROTOR REMOVALMake alignment dots on the outer and inner rotors for ease of reassembly.
Fig. 96: Removing Outer Rotor/Inner Rotor

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INSTALLATION SERVICE POINTS >>A<< INNER ROTOR/OUTER ROTOR INSTALLATION Apply engine oil to the rotors. Then install the rotors, ensuring that the alignment
dots made at disassembl
y are
properl
y ali
gned.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor