MITSUBISHI ENDEAVOR 2004 Service Repair Manual

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

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