2004 MITSUBISHI ENDEAVOR check engine

3. Insert the front end of the pipe into the water pump. >>B<< THERMOSTAT HOUSING GASKET INSTALLATION Install the thermostat housing gasket so that the tab is positioned as shown in the
illustration.
Fig. 47: Installing Thermostat Housing Gasket

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>>C<< THERMOSTAT INSTALLATION 1. Check that the rubber ring is free from damage and seated correctly in the
thermostat flange.
2. Install the thermostat as shown in the illustration. The jiggle valve must be at
the to
p position.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

2. Check to see that the dowel pin of the camshaft is located at the position
shown.
Fig. 56: Checking Dowel Pin Position Of Camshaft

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>>B<< LASH ADJUSTER INSTALLATION Fit the lash adjuster onto the rocker arm without allowing diesel fuel to spill out. Fit
special tool MD998443 to prevent the lash adjuster coming from free and falling to
the floor.
CAUTION: If the lash adjuster is re-used, clean the lash adjuster.
(Refer to LASH ADJUSTER INSPECTION
.)

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 60: Identifying Special Tools MD998713 And MB991559

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INSPECTION ROCKER ARM SHAFT Check the rocker arm mounting areas of the rocker arm shafts for wear or damage.
Replace as necessary. ROCKER ARM 1. Check the roller surface and replace the rocker arm if recesses, damage or heat
seizure is observed.
2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 61: Checking Roller Surface Rocker Arm

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Check roller rotation and replace the rocker arm if uneven rotation or roller
backlash of the roller is observed.
3. Check the inside diameter and replace the rocker arm if damage or seizure is
observed.
CAMSHAFT 1. Check the camshaft bearing journals for damage and binding. If the journals
are binding, check the cylinder head for damage. Also check the cylinder head
for clogged oil holes.
2. Check the tooth surface of the distributor drive gear teeth of the camshaft and
replace if abnormal wear is evident.
3. Check the cam surface for abnormal wear and damage and replace if necessary.
Also measure the cam height and replace if out of minimum limit.
Standard value:
Intake 37.39 mm (1.472 inches)
Exhaust 37.14 mm (1.462 inches)
Minimum limit:
2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 70: Pushing Plunger Downward To Fill Fuel

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
9. Remove the lash adjuster from the container, then stand the lash adjuster with
its plunger at the top. Push the plunger firmly and check that it does not move.
NOTE: If the lash adjuster contracts or moves, repeat steps 7
through 9 again to fill it with diesel fuel completely.
Replace the lash adjuster if it still contracts or moves
after performing these steps.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 71: Removing Lash Adjuster From The Container And Checking Move

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
10. Stand the lash adjuster upright to prevent diesel fuel from spilling out. Do not
allow the lash adjuster to become contaminated by dirt or other foreign matter.
Install the lash adjuster onto the engine as soon as possible.
CYLINDER HEAD AND VALVES REMOVAL AND INSTALLATION
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. 82: Inspecting Cylinder Head To Meet Its Specification

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
VALVE 1. Check the valve face for correct contact. If incorrect, reface using a valve
refacer. The valve should make a uniform contact with the seat at the center of
the valve face.
2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor