2004 MITSUBISHI ENDEAVOR engine

Fig. 147: Installing Bearing Cap/Bearing Bolt

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2. Tighten the bearing cap bolts to specified torque in the sequence shown in the
illustration.
Tightening torque: 74+/-4 N.m (54+/-3 ft-lb)
3. Check that the crankshaft rotates smoothly.
4. Check the end play. If it exceeds the limit value, replace the thrust bearing.
Standard value: 0.05 - 0.25 mm (0.002 - 0.009 inch)
Limit: 0.3 mm (0.01 inch)

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 148: Checking End Play Of Thrustbearing

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>>F<< CRANKSHAFT REAR OIL SEAL INSTALLATION Using special tool MD998718, press-fit a new crankshaft rear oil seal into the oil
seal case.
2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 149: Installing Crankshaft Rear Oil Seal

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>>G<< OIL SEAL CASE INSTALLATION 1. Apply the sealant Mitsubishi Genuine Part number MD970389 or equivalent to
the oil seal case.
2. Apply a small amount of engine oil to the entire circumference of the oil seal
lip section, and place the oil seal case on the cylinder block. NOTE: Install the oil seal case within 15 minutes after applying
liquid gasket. Then wait at least one hour. Do not start the
engine or let engine oil or coolant touch the sealant during
that time.
2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 150: Installing Oil Seal Case

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INSPECTION CRANKSHAFT JOURNAL OIL CLEARANCE < PLASTIC GAUGING MATERIAL METHOD > 1. Remove oil from the crankshaft journal and crankshaft bearing inner surface.
2. Install the crankshaft.
3. Cut plastic gauging material to the same length as the width of the bearing and
place it on the
journal in
parallel with its axis.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 151: Placing Plastic Gauging Material As Width Of The Bearing On The Journal In Parallel

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4. Install the crankshaft bearing cap carefully and tighten the bolts to the specified
torque.
Tightening torque: 74+/-4 N.m (54+/-3 ft-lb)
5. Carefully remove the crankshaft bearing cap.
6. Measure the width of the smashed plastic gauging material at its widest section
by using a scale printed on the plastic gauging material bag.
Standard Value:
0.02 - 0.03 mm (0.0008 - 0.0012 inch) < No.1, 4 >

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

0.03 - 0.04 mm (0.0012 - 0.0016 inch) < No.2, 3 >
Limit: 0.1 mm (0.003 inch)
Fig. 152: Measuring Width Of Smashed Plastic Gauge

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CRANKSHAFT REAR OIL SEAL 1. Check the oil seal lip for wear and damage.
2. Check the rubber for deterioration or hardening.
3. Check the oil seal case for cracks and damage. CYLINDER BLOCK 1. Visually check for scratches, rust, and corrosion. Use a flaw detecting agent for
2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

the check. If defects are evident, correct or replace.
2. Using a straightedge and feeler gauge, check the block top surface for warpage.
Make sure that the surface is free from gasket chips and other foreign matter.
Standard value: 0.05 mm (0.002 inch)
Limit: 0.1 mm (0.003 inch)
3. If the distortion is excessive, correct within the allowable limit or replace.
Grinding limit: *0.2 mm (0.008 inch)
*Includes/combined with cylinder head grinding.
Cylinder block height (when new):
227.9 - 228.1 mm (8.972 - 8.980 inches)
Fig. 153: Checking Cylinder Block

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2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

4. Check the cylinder walls for scratches and seizure. If defects are evident,
correct (bored to an oversize) or replace.
5. Using a cylinder gauge, measure the cylinder bore and cylindricality. If worn
badly, correct by boring the cylinders to an oversize and replace pistons and
piston rings. Measure at the points shown in the illustration.
STANDARD VALUE:
Cylinder Inside Diameter: 95.0 mm (3.740 inches)
Cylindricality: 0.01 mm (0.0003 inch)
Fig. 154: Measuring Cylinder Bore

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BORING CYLINDER
2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor