MITSUBISHI ENDEAVOR 2004 Service Repair Manual

Fig. 22: Aligning The Location Of Pin And Pin Hole

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
4. Install the crankshaft sprocket to the crankshaft.
>>C<< AUTO-TENSIONER INSTALLATION If the auto-tensioner rod is fully extended, reset it as follows:
1. Clamp the auto-tensioner in the vise with soft jaws.
2. Push in the rod little b
y little with the vise until set hole A in the rod is ali
gned

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

with hole B in the cylinder.
Fig. 23: Installing Auto
-Tensioner

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3. Insert a wire [1.4 mm (0.055 inch) in diameter] into the set holes. This auto-
tensioner setting wire will be used during timing belt alignment.
4. Unclamp the auto-tensioner from the vise.
>>D<< TIMING BELT INSTALLATION
CAUTION: Do not turn the camshaft when the piston in No. 1
cylinder is at top dead center on the compression
stroke. Doing so can cause the lifted valve to hit
against the piston, damaging parts.

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

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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. 26: Install The Timing Belt On Each Sprocket And Pulley

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
7. Install special tool MD998767 to the tensioner pulley. While pushing the
pulley lightly against the belt using the special tool, tighten the flange bolt.
Tightening torque: 48+/-6 N.m (35+/-4 ft-lb)

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 27: Install Special Tool MD998767 To The Tensioner Pulley

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 28: Identifying Parts Of Engine Overhaul Timing Belt

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
8. Check to see that the timin
g marks of all the s
prockets are in ali
gnment.

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. 31: Checking Auto
-Tensioner Was Can Be Removed Without
Resistance

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
15. If the metal wire offers resistance when removed, repeat the previous steps 10
through 13 until proper belt tension is obtained.
>>E<< ENGINE SUPPORT BRACKET, RIGHT INSTALLATION The mounting bolts of the right engine support bracket must be tightened in the
order shown in the illustration.
Tightening torque: 45+/-5 N.m (34+/-3 ft-lb)
Bolt length
85 mm
(33.5 inch
) - Bolt
3

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor