2004 MITSUBISHI ENDEAVOR engine

1. Oversize pistons to be used should be determined on the basis of the largest
bore cylinder.
PISTON SIZE IDENTIFICATION
Fig. 155: Identifying Piston

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2. Measure the outside diameter of the piston to be used. Measure it in the thrust
direction as shown.
SIZE
IDENTIFICATION
MARK
0.25 mm (0.010 in)
Oversize Diameter
0.25
0.50 mm (0.020 in)
Overside Diameter
0.50
NOTE: Size mark is stamped on the piston top.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

3. Based on the measured piston Outside Diameter (OD), calculate the boring
finish dimension.
Boring finish dimension = Piston OD + (clearance between piston OD
and cylinder) - 0.02 mm (0.0008 inch) (honing margin)
4. Bore all cylinders to the calculated boring finish dimension.
5. Hone to the final finish dimension (piston OD + clearance between piston OD
and cylinder).
STANDARD VALUE:
Cylinder Inside Diameter: 95.0 mm (3.740 inches)
Cylindricality: 0.01 mm (0.0003 inch)
6. Check the clearance between the piston and cylinder.
Clearance between piston and cylinder:
0.02 - 0.04 mm (0.0008 - 0.0015 inch) SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS
CAUTION: To prevent distortion that may result from
temperature rise during honing, bore cylinders in
the order of number 2, number 4, number 6,
number 1, number 3 and number 5.
NOTE: When boring cylinders, finish all six cylinders to the same
oversize. Do not bore only one cylinder to an oversize.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 156: Fastener Tightening Specifications (1 Of 3)

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2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 157: Fastener Tightening Specifications (2 Of 3)

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y of MITSUBISHI MOTOR SALES OF AMERICA
.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 158: Fastener Tightening Specifications (3 Of 3)

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GENERAL SPECIFICATIONS
2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 159: General Specification Chart

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SERVICE SPECIFICATIONS
2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 160: Service Specifications Chart (1 Of 3)

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2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 161: Service Specifications Chart (2 Of 3)

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2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor