MITSUBISHI ENDEAVOR 2004 Service Repair Manual

Fig. 59: Installing The Camshaft Oil Seal

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2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 60: Identifying Special Tools MD998713 And MB991559

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INSPECTION ROCKER ARM SHAFT Check the rocker arm mounting areas of the rocker arm shafts for wear or damage.
Replace as necessary. ROCKER ARM 1. Check the roller surface and replace the rocker arm if recesses, damage or heat
seizure is observed.
2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 61: Checking Roller Surface Rocker Arm

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2. Check roller rotation and replace the rocker arm if uneven rotation or roller
backlash of the roller is observed.
3. Check the inside diameter and replace the rocker arm if damage or seizure is
observed.
CAMSHAFT 1. Check the camshaft bearing journals for damage and binding. If the journals
are binding, check the cylinder head for damage. Also check the cylinder head
for clogged oil holes.
2. Check the tooth surface of the distributor drive gear teeth of the camshaft and
replace if abnormal wear is evident.
3. Check the cam surface for abnormal wear and damage and replace if necessary.
Also measure the cam height and replace if out of minimum limit.
Standard value:
Intake 37.39 mm (1.472 inches)
Exhaust 37.14 mm (1.462 inches)
Minimum limit:
2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Intake 36.89 mm (1.452 inches)
Exhaust 36.64 mm (1.443 inches)
Fig. 62: Measuring Cam

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CAUTION:
The lash adjusters are precision-engineered
mechanisms. Do not allow them to become
contaminated by dirt or other foreign
substances. Do not attempt to disassemble the lash
adjusters. Use only fresh diesel fuel to clean the lash

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

1. Prepare three containers and approximately 5 DM< SD >3< /SD > (30.5 quart)
of diesel fuel. Into each container, pour enough diesel fuel to completely cover
a lash adjuster when it is standing upright. Then, perform the following steps
with each lash adjuster.
Fig. 63: Cleaning Lash Adjuster

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2. Place the lash adjuster in container A and clean its outside surface.
adjusters.
NOTE: Use a nylon brush if deposits are hard to remove.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 64: Cleaning Lash Adjuster Outside Surface

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3. While gently pushing down the internal steel ball using wire [0.5 mm (0.020
inch) in diameter] or special tool MD998442, move the plunger through five to
ten strokes until it slides smoothly. In addition to eliminating stiffness in the
plunger, this operation will remove dirty oil.
CAUTION: The steel ball spring is extremely weak, so the
lash adjuster's functionality may be lost if the air
bleed wire is pushed in hard.
NOTE: If the plunger remains stiff or the mechanism appears
otherwise abnormal, replace the lash adjuster.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 65: Replacing Lash Adjuster

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4. Remove the lash adjuster from the container. Then, push down the steel ball
gentl
y and
push the
plun
ger to eliminate diesel fuel from the
pressure chamber.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 66: Eliminating Diesel Fuel From The Pressure Chamber

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5. Place the lash adjuster in container B. Then, gently push down the internal steel
ball using a wire [0.5 mm (0.020 inch) in diameter] or special tool MD998442
and move the plunger through five to ten strokes until it slides smoothly. This
o
peration will clean the lash ad
juster's
pressure chamber.
CAUTION: The steel ball spring is extremely weak, so the
lash adjuster's functionality may be lost if the air
bleed wire is pushed in hard.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 67: Using Special Tool MD998442

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
6. Remove the lash adjuster from the container. Then, push down the steel ball
gentl
y and
push the
plun
ger to eliminate diesel fuel from the
pressure chamber.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 68: Pushing Down The Steel Ball And Plunger To Eliminate Diesel

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
7. Place the lash adjuster in container C. Then, gently push down the internal steel
ball using a wire [0.5 mm (0.020 inch) in diameter] or special tool MD998442.
CAUTION: Do not use container C for cleanin
g. If cleanin
g is
performed in container C, foreign matter could
enter the pressure chamber when the chamber is
filled with diesel fuel.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor