2004 MITSUBISHI ENDEAVOR engine

Fig. 108: Installing Drain Plug Gaske
t
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
INSPECTION OIL PUMP 1. Check the tip clearance.
Standard value: 0.06 - 0.18 mm (0.003 - 0.007 inch)
Fig. 109: Checking Tip Clearance

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2. Check the side clearance.
Standard value: 0.04 - 0.10 mm (0.002 - 0.003 inch)

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 110: Checking Side Clearance

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3. Check the body clearance.
Standard value: 0.10 - 0.18 mm (0.004 - 0.007 inch)
Limit: 0.35 mm (0.013 inch)

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 111: Checking Body Clearance

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PISTON AND CONNECTING ROD REMOVAL AND INSTALLATION
2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 112: Removing/Installing Piston And Connecting Rod

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REMOVAL SERVICE POINTS << A >> CONNECTING ROD CAP REMOVAL 1. Mark the cylinder number on the side of the connecting rod big end for correct
reassembly.
2. Kee
p the removed connectin
g rods, ca
ps, and bearin
gs in order accordin
g to

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

the cylinder number.
Fig. 113: Removing Connecting Rod Cap

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< > PISTON PIN REMOVAL
CAUTION: The clearance between the piston and the piston pin
is a tight fit at room temperature. Therefore, be sure
to heat the piston before pulling out the piston pin.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

1. Heat the piston approximately 70°C (158°F) and pull out the piston pin.
Fig. 114: Removing Piston Pin

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INSTALLATION SERVICE POINTS >>A<< PISTON PIN INSTALLATION 1. When replacing the piston, note the cylinder bore size mark on the cylinder
block as illustrated, and select a
piston accordin
g to the followin
g table.
Use care since the piston is hot after heating.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 115: Installing Piston Pin Position

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2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 116: Identifying Piston Pin Size Chart

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2. Heat the piston to approximately 70°C (158°F).
NOTE: The piston size mark shows on the top of the piston.
CAUTION: Appl
y ample coat of en
gine oil to the peripher
y of
the piston pin and the hole of the connecting rod
small end. The clearance between the piston and
the piston pin is a tight fit at room temperature.
Therefore, be sure to heat the piston before
inserting the piston pin. Use care since the
piston is hot after heating.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor