MITSUBISHI ENDEAVOR 2004 Service Repair Manual

1. Heat the piston approximately 70°C (158°F) and pull out the piston pin.
Fig. 114: Removing Piston Pin

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INSTALLATION SERVICE POINTS >>A<< PISTON PIN INSTALLATION 1. When replacing the piston, note the cylinder bore size mark on the cylinder
block as illustrated, and select a
piston accordin
g to the followin
g table.
Use care since the piston is hot after heating.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 115: Installing Piston Pin Position

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2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 116: Identifying Piston Pin Size Chart

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2. Heat the piston to approximately 70°C (158°F).
NOTE: The piston size mark shows on the top of the piston.
CAUTION: Appl
y ample coat of en
gine oil to the peripher
y of
the piston pin and the hole of the connecting rod
small end. The clearance between the piston and
the piston pin is a tight fit at room temperature.
Therefore, be sure to heat the piston before
inserting the piston pin. Use care since the
piston is hot after heating.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 117: Heating Piston

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3. With the front mark of the connecting rod and that of the piston located on the
same side, insert the
piston
pin.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 118: Identifying Mark On Piston And Connecting Rod

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4. Set the snap ring into the other side of the piston pin hole.
5. Check that the
piston moves smoothl
y.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 119: Checking Piton Moves Smoothly

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>>B<< OIL RING INSTALLATION 1. Fit the oil ring spacer into the piston ring groove.
2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 120: Installing Oil Ring Spacer

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2. Install the upper side rail by hand.
To install the side rail, first fit one end of the rail into the piston groove, then
press the remaining portion into the position. See illustration.
3. Install the lower side rail in the same procedure as described in ste
p 2.
NOTE: The side rails and spacer may be installed in either
direction.
CAUTION: Do not use any piston ring expander when
installing the side rail. It will break the side rail.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 121: Installing Side Rail

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4. Make sure that the side rails move smoothly in both directions.
>>C<< PISTON RING NO.2/PISTON RING NO.1 INSTALLATION 1. To prevent wrong installation, check the identification mark of each piston
ring. The identification mark is stamped near the ring gap:
Identification mark
2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Number 1 ring: 1T
Number 2 ring: 2T
Fig. 122: Identifying And Installing Piston Ring

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NOTE: Size marks on piston rings are as follows.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 123: Identifying Piston Ring Size Chart

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Using a piston ring expander, fit the number 2 piston ring into the number 2
groove of piston.
NOTE: Install the piston rings with their identification mark
facing up, to the piston crown side.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor