2004 MITSUBISHI ENDEAVOR Intake

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

Intake 36.89 mm (1.452 inches)
Exhaust 36.64 mm (1.443 inches)
Fig. 62: Measuring Cam

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CAUTION:
The lash adjusters are precision-engineered
mechanisms. Do not allow them to become
contaminated by dirt or other foreign
substances. Do not attempt to disassemble the lash
adjusters. Use only fresh diesel fuel to clean the lash

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

Fig. 76: Identifying Intake And Exhaust Valve Seating

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2. Using special tool MD998774, install a new stem seal to the valve guide.
Valve stem seal identification color
Identification color
Intake: GRAY
Exhaust: GRAY GREEN
CAUTION: Always use the special tool to install the valve
stem seal. Improperly installed valve stem seals
may leak oil.

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

< Intake > 110.30 mm (4.343 inches)
< Exhaust > 112.11 mm (4.414 inches)
Minimum limit:
< Intake > 109.80 mm (4.323 inches)
< Exhaust > 111.61 mm (4.394 inches)
Fig. 84: Measuring Valve Length

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VALVE SPRINGS 1. Measure the free height of the spring and, if it is smaller than the minimum
limit, replace the spring.
Standard value: 51.0 mm (2.01 inches)
Minimum limit: 50.0 mm (1.97 inches)
2. Measure the squareness of the spring and, if the limit is exceeded, replace the
s
prin
g.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Measure the clearance between the valve guide and valve stem. If the limit is
exceeded, replace the valve guide, valve, or both.
Standard value:
< Intake > 0.02 - 0.05 mm (0.0008 - 0.0019 inch)
< Exhaust > 0.04 - 0.06 mm (0.0016 - 0.0023 inch)
Limit:
< Intake > 0.10 mm (0.003 inch)
< Exhaust > 0.15 mm (0.005 inch)
Fig. 86: Measuring Clearance Between Valve Stem And Vale Guide

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VALVE SEAT Assemble the valve, then measure the valve stem
projection between the end of the

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

valve stem and the spring seating surface. If the measurement exceeds the specified
limit, replace the valve seat.
Standard value:
< Intake > 48.30 mm (1.902 inches)
< Exhaust > 51.71 mm (2.036 inches)
Limit:
< Intake > 48.80 mm (1.921 inches)
< Exhaust > 52.21 mm (2.056 inches)
Fig. 87: Measuring Valve Stem Projection

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor