2004 MITSUBISHI ENDEAVOR crankshaft pulley

Fig. 5: Holding The Drive Plate Or Flywheel Using Special Tool MD998781

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Clean the bolt hole in crankshaft bolt, damper pulley seating surface and the
washer.
3. Degrease the cleaned seating surface of the damper pulley.
4. Install the damper pulley.
5. Apply a minimum amount engine oil to the thread and lower flange of the
crankshaft bolt.
6. Install the washer to the crankshaft bolt with its inside chamfered side toward
the bolt head.
7. Tighten the crankshaft bolt to the specified torque.
Tightening torque: 185+/-5 N.m (137+/-3 ft-lb)

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

MD998715: Pins MD998767: Tensioner Pulley Wrench MD998769: Crankshaft Spacer
REMOVAL SERVICE POINTS << A >> TIMING BELT REMOVAL 1. Mark the belt running direction for reinstallation.
2. Loosen the tensioner pulley bolt, and then remove
the timing belt.
CAUTION: Water or oil on the belt shortens its life drasticall
y, so
the removed timing belt, sprocket, and tensioner
must be kept free from oil and water. These parts
should not be washed or immersed in solvent.
Replace parts if contaminated. If there is oil or water
on any part, check the front case oil seal, camshaft
oil seal, and water pump for leaks.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

1. Install special tool MD998769 and the crankshaft pulley washer, and then
tighten the crankshaft bolt.
2. Align the timing mark on the crankshaft sprocket with the timing mark on the
oil pump case, and then rotate the sprocket three teeth counterclockwise.
Fig. 24: Aligning The Timing Mark On Crankshaft Sprocket & Timing
Mark On Oil Pump Case

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3. Align the timing mark on the left bank camshaft sprocket with the timing mark
on the rocker cover.
4. Align the timing mark on the right bank camshaft sprocket with the timing
mark on the rocker cover.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 25: Align The Timing Mark On The Right Bank Camshaft Sprocket With Timing Mark On Rocker Cover

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
5. Align the timing mark on the crankshaft sprocket with the timing mark on the
oil pump case.
6. Install the timing belt on each sprocket and pulley in the following sequence.
Do not leave the belt slack between each sprocket and pulley.
1. Crankshaft sprocket
2. Idler pulley
3. Left bank camshaft sprocket
4. Water pump pulley
5. Right bank camshaft sprocket
6. Tensioner
pulle
y

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 29: Checking Timing Marks Of All The Sprockets Are In Alignment

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
9. Rotate the crankshaft a quarter turn counterclockwise. Then rotate it back
clockwise to verify that all the timing marks are aligned.
10. Loosen the flange bolt securing the tensioner pulley, and then mount special
tool MD998767 and a torque wrench on the tensioner pulley.
11. Torque it to 4.4 N.m (39 in-lb) with the torque wrench.
12. While holding the tensioner pulley in position, tighten the flange bolt to the
specified torque.
Ti
ghtenin
g tor
que: 48+
/-6 N.m (35+
/-4 f
t-lb)

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 30: Holding The Tensioner Pulley In Position, Tighten The Flange Bolt

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
13. Rotate the crankshaft two turns clockwise and leave it alone for approximately
five minutes.
14. Check to see whether the metal wire inserted when the auto-tensioner was
installed can be removed without any resistance.
If the metal wire can be removed without any resistance, it means that the belt
has a proper tension. Therefore, remove the metal wire. In this condition, check
that the rod protrusion of the auto-tensioner is within the standard value.
Standard value: 4.8 - 6.0 mm (0.19 - 0.24 inch)

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 17: Loosening Tensioner Pulley Lock Nut

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Adjust the belt tension to the standard value by turning the adjusting bolt. The
tension will increase when turning the adjusting bolt clockwise, and decrease
when turning counterclockwise.
3. Tighten the lock nut to the specified torque.
Tightening torque: 49+/-9 N.m (36+/-7 ft-lb)
4. Tighten the adjusting bolt.
Tightening torque: 5.0+/-1.0 N.m (44+/-9 in-lb)
5. Check the belt deflection amount and tension, and readjust if necessary.
IGNITION TIMING CHECK
CAUTION: Check after turning the crankshaft one or more
rotations clockwise.

2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor

Fig. 44: Removing And Installing Camshaft Oil Seal

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Required Special Tools:
MB990767: End Yoke Holder MB991559: Camshaft Oil Seal Adapter MD998713: Camshaft Oil Seal Installer MD998715: Crankshaft Pulley Holder Pin
REMOVAL SERVICE POINTS << A >>CAMSHAFT SPROCKET REMOVAL Use s
pecial tools MD998715 and MB990767 to remove the camshaft s
procket.

2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor