MITSUBISHI ENDEAVOR 2004 Service Repair Manual

VALVE SEAT RECONDITIONING PROCEDURE1. Correct to that the valve seat width and angle are as specified in the illustration.
Fig. 88: Identifying Valve Seat Specifications

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2. After correcting the valve seat, lap the valve and valve seat using lapping
compound. Then, check the valve stem projection.
VALVE SEAT REPLACEMENT PROCEDURE
CAUTION: Before correcting the valve seat, check the clearance
between the valve guide and valve and, if necessary,
replace the valve guide.CAUTION: Before replacing the valve seat, check the valve
guide and, if necessary, replace the valve guide.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

1. Cut the valve seat from the inside to thin the wall thickness. Then, remove the
valve seat.
Fig. 89: Cutting Valve Seat

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2. Rebore the valve seat hole in the cylinder head to a selected oversize valve seat
diameter.
SEAT RING HOLE DIAMETER:
Intake valve
0.3 oversize 37.80 - 37.83 (1.4882 - 1.4894 inches)
0.6 oversize 38.10 - 38.13 mm (1.5000 - 1.5012 inches)
Exhaust valve
0.3 oversize 34.80 - 34.83 mm (1.3701 - 1.3713 inches)

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

0.6 oversize 35.10 - 35.13 mm (1.3819 - 1.3831 inches)
Fig. 90: Inspecting Seat Ring Hole Diameter

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3. Before fitting the valve seat, either heat the cylinder head up to approximately
250°C (482°F) or cool the valve seat in liquid nitrogen, to prevent the cylinder
head bore from galling.
4. Using a valve seat cutter, correct the valve seat to the specified width and
angle. Using a valve seat cutter, correct the valve seat to the specified width
and angle. See "VALVE SEAT RECONDITIONING PROCEDURE
" on
the
previous
page.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

VALVE GUIDE REPLACEMENT PROCEDURE1. Remove the snap ring from the exhaust valve guide.
2. Using a press, remove the valve guide toward the cylinder head gasket surface.
Fig. 91: Identifying Valve Guide Replacement Procedure

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3. Re-bore the valve guide hole of the cylinder head so that it fits the press-fitted
oversize valve guide.
Valve Guide Hole Diameter:
CAUTION: Do not install a valve guide of the same size
again.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

0.05 oversize 11.05 - 11.07 mm (0.4350 - 0.4358 inch)
0.25 oversize 11.25 - 11.27 mm (0.4429 - 0.4437 inch)
0.50 oversize 11.50 - 11.52 mm (0.4528 - 0.4535 inch)
Fig. 92: Measuring Valve Guide

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4. Install the new snap ring into the groove of exhaust valve guide.
5. Press-fit the valve guide until it protrudes 14 mm (0.55 inch) from the cylinder
head top surface as shown in the illustration.
NOTE: When press-fitting the valve guide, work from the cylinder
head top surface.
NOTE: After installing the valve guides, insert new valves in them
2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

OIL PAN AND OIL PUMP REMOVAL AND INSTALLATION Fig. 93: Removing/Installing Oil Pan And Oil Pump

to check for sliding condition.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

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.
REQUIRED SPECIAL TOOL
MD998054: Oil Pressure Switch Socket Wrench MD998717: Crankshaft Front Oil Seal Installer
REMOVAL SERVICE POINT << A >> OIL PAN, LOWER REMOVAL 1. Remove the lower oil pan mounting bolts.
2. Remove the lower oil pan by tapping on its side with a plastic hammer (mallet)
through a wooden plank held against it. < B > OIL PAN, UPPER REMOVAL 1. Remove the long bolts "A" shown in the illustration first.
CAUTION: Do not use a scraper or special tool to remove
the oil pan.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 94: Identifying Long Bolt
s
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2. Remove all other bolts.
3. Remove the oil pan.
4. Screw M10 bolts into the two bolt holes in the oil pan to break the joint and
remove the oil pan.
Fig. 95: Breaking Joint And Remove Oil Pan

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CAUTION: Do not use a scraper or special tool to remove
the oil pan.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

<< C >> OUTER ROTOR/INNER ROTOR REMOVALMake alignment dots on the outer and inner rotors for ease of reassembly.
Fig. 96: Removing Outer Rotor/Inner Rotor

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INSTALLATION SERVICE POINTS >>A<< INNER ROTOR/OUTER ROTOR INSTALLATION Apply engine oil to the rotors. Then install the rotors, ensuring that the alignment
dots made at disassembl
y are
properl
y ali
gned.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 97: Installing Outer/Inner Rotor

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>>B<< OIL PUMP CASE ASSEMBLY INSTALLATION 1. Clean the gasket mating surfaces of oil pump case and cylinder block.
2. Apply a 3 mm (0.1 inch) diameter bead of sealant (Mitsubishi Genuine Parts
number MD970389 or equivalent) to the oil pump case.
Apply sealant as indicated by the broken line in the illustration; the grooves
must be traced and the bolt holes must be surrounded with a bead of sealant.
3. Install the oil pump case assembly to the front of the cylinder block.
NOTE: Be sure to install the oil pump case quickly while the
sealant is wet (within 15 minutes).

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor