2004 MITSUBISHI ENDEAVOR table

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. 124: Using Piston Ring Expander

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3. Install the number 1 piston ring in the same manner as step 2.
>>D<< CONNECTING ROD BEARING INSTALLATION 1. Measure the crankshaft pin diameter and confirm its classification from the
following table. In the case of a crankshaft supplied as a service part,
identification colors/marks of its
pins are
painte
d/stam
ped at the
positions

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA
.
2. From the above table, select a bearing whose size is appropriate for the
crankshaft pin outside the diameter. For example, if the crankshaft pin outside
diameter Identification color is "yellow" and the connecting rod Identification
mark is "2," select a bearing whose Identification color is "green."
For example, if the crankshaft pin outside diameter Identification color is
"yellow" and the connecting rod Identification mark is "2," select a bearing
whose Identification color is "green."
If there is no identification color paint on the crankshaft, measure the pin
outside diameter and select bearing appropriate for the measured value.
Fig. 127: Identifying Mark Oncarnkshaft Bearing

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3. Install the selected bearin
g in the bi
g end and in the ca
p of the connectin
g rod.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 130: Inserting Piston And Connecting Rod Assembly Into Cylinder

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
5. Using a suitable piston ring compressor tool, install the piston and connecting
rod assembly into the cylinder block.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

1. Measure the crankshaft journal diameter and confirm its classification from the
following table. In the case of a crankshaft supplied as a service part,
identification colors/marks of its journals are painted/stamped at the positions
shown in the illustration.
Fig. 141: Identifying Color On Crankshaft

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. The cylinder block bearing bore diameter identification marks are stamped at
the
position shown in the illustration from left to ri
ght, be
ginnin
g at No. 1.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 143: Carnkshaft Identification Marking Char
t
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3. From the above table, select a bearing whose size is appropriate for the
crankshaft journal outside diameter. If the crankshaft journal outside diameter
ID color is "yellow" and the cylinder block bearing bore ID mark is "III," for
example, select a bearing whose ID color is "green" < No.1, 4 > or "red" <
No.2, 3 >.
If there is no ID color paint on the crankshaft, measure the journal outside
diameter and select a bearing appropriate for the measured valve.
Fig. 144: Identifying Color On Bearing

Courtes
y of MITSUBISHI MOTOR SALES OF AMERICA
.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

2004 ENGINE
Engine - Endeavor
GENERAL DESCRIPTION The 6G75 (3.8L) engine is a six-cylinder engine. The cylinder numbers are assigned
as 1-3-5 for the right bank and 2-4-6 for the left bank from the front of the engine
(timing belt side). This engine is fired in the order of 1-2-3-4-5-6 cylinders.
Fig. 1: General Specification Table

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
DIAGNOSIS
2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor


2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor

Fig. 12: Identifying Standard Value Specification Table

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3. Tighten the tension pulley fixing nut.
Tightening torque: 49+/-10 N.m (36+/-7 ft-lb)
POWER STEERING DRIVE BELT TENSION CHECK Check the drive belt tension by the following procedure. < WHEN USING SCAN TOOL MB991958 > Required Special Tools:
MB991958: Scan Tool (MUT-III Sub Assembly) [MB991824: Vehicle
Communication Interface (V.C.I.)] MB991668: Belt Tension Meter Set NOTE: Because the frequency depends on the belt material,
confirm Part No. shown on the reverse of the belt.

2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor