MITSUBISHI ENDEAVOR 2004 Service Repair Manual

Fig. 69: Placing Lash Adjuster In Container C

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
8. Stand the lash adjuster with its plunger at the top, then push the plunger
downward firmly until it moves through its greatest possible stroke. Return the
plunger slowly, then release the steel ball and allow the pressure chamber to
fill with diesel fuel.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 70: Pushing Plunger Downward To Fill Fuel

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
9. Remove the lash adjuster from the container, then stand the lash adjuster with
its plunger at the top. Push the plunger firmly and check that it does not move.
NOTE: If the lash adjuster contracts or moves, repeat steps 7
through 9 again to fill it with diesel fuel completely.
Replace the lash adjuster if it still contracts or moves
after performing these steps.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 71: Removing Lash Adjuster From The Container And Checking Move

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
10. Stand the lash adjuster upright to prevent diesel fuel from spilling out. Do not
allow the lash adjuster to become contaminated by dirt or other foreign matter.
Install the lash adjuster onto the engine as soon as possible.
CYLINDER HEAD AND VALVES REMOVAL AND INSTALLATION
2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 72: Removing/Installing Cylinder Head And Valves

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REQUIRED SPECIAL TOOLS:
MD998051: Cylinder Head Bolt Wrench MD998735: Valve Spring Compressor MD998772: Valve Spring Compressor MD998774: Valve Stem Seal Installer

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

REMOVAL SERVICE POINTS << A >> CYLINDER HEAD BOLT REMOVAL Use special tool MD998051 to loosen the cylinder head bolt.
Fig. 73: Removing Cylinder Head Bolt

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< > RETAINER LOCK REMOVAL 1. Using special tool MD998735 or MD998772, compress the spring.
2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 74: Compressing Spring

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2. Remove the retainer locks.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 75: Removing Spring Using Special Tool MD998772

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INSTALLATION SERVICE POINTS >>A<< VALVE STEM SEAL INSTALLATION 1. Install the valve spring seat. NOTE: Tag removed valves, springs and other components, noting
their cylinder numbers and locations to facilitate
reassembly. Store these components safely.
CAUTION:
Valve stem seals for intake valves and for
exhaust valves are different. Be sure to
install the correct ones.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 76: Identifying Intake And Exhaust Valve Seating

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Using special tool MD998774, install a new stem seal to the valve guide.
Valve stem seal identification color
Identification color
Intake: GRAY
Exhaust: GRAY GREEN
CAUTION: Always use the special tool to install the valve
stem seal. Improperly installed valve stem seals
may leak oil.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 77: Using Special Tool MD998774 For Install New Stem Seal

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
>>B<< VALVE SPRING INSTALLATION Install the valve s
prin
g end with its identification color toward the s
prin
g retainer.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 78: Installing Valve Spring And Identifying Colors

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>>C<< RETAINER LOCK INSTALLATION Using special tool MD998735 or MD998772, compress the valve spring and insert
the retainer lock into position. NOTE: The valve spring, if excessively compressed, causes the
bottom end of retainer to damage the stem seal.
2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor