MITSUBISHI ENDEAVOR 2004 Service Repair Manual

Fig. 134: Installing Connecting Rod Cap Nu
t
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INSPECTION PISTON Replace the piston if scratches or seizure is evident on its surfaces (especially the
thrust surface). Replace the piston if it is cracked. PISTON PIN 1. Insert the piston pin into the piston pin hole with a thumb. You should feel a
slight resistance. Replace the piston pin if it can be easily inserted or there is
excessive play.
2. The piston and piston pin must be replaced as an assembly. PISTON RING 1. Check the piston ring for damage, excessive wear, and breakage. Replace if
defects are evident. If the piston has been replaced with a new one, the piston
rings must also be replaced with new ones.
2. Check for clearance between the piston ring and ring groove. If the limit is
exceeded, replace the ring or piston, or both.
Standard Value:
Number 1: 0.03 - 0.07 mm (0.0012 - 0.0027 inch)
Number 2: 0.02 - 0.06 mm (0.0008 - 0.0023 inch)
Limit: 0.1 mm (0.003 inch)
2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 135: Checking Piston Pin For Damage

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3. Insert the piston ring into the cylinder bore. Force the ring down with a piston,
the piston crown being in contact with the ring, to correctly position it at right
angles to the cylinder wall. Then, measure the end gap with a feeler gauge.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

If the ring gap is excessive, replace the piston ring.
Standard value:
Number 1: 0.25 - 0.40 mm (0.010 - 0.016 inch)
Number 2: 0.35 - 0.50 mm (0.014 - 0.020 inch)
Oil: 0.10 - 0.35 mm (0.004 - 0.014 inch)
Limit:
Number 1, Number 2: 0.8 mm (0.03 inch)
Oil: 1.0 mm (0.03 inch)

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 136: Measuring End Gap

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CRANKSHAFT PIN OIL CLEARANCE < PLASTIC GAUGING MATERIAL METHOD > The crankshaft oil clearance can be measured easily by using plastic gauging
material, as follows:
2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

1. Remove oil from the crankshaft pin and the bearing inner surface.
2. Cut plastic gauging material to the same length as the width of the bearing and
place it on the pin in parallel with its axis.
3. Install the connecting rod cap carefully and tighten the nuts to the specified
torque.
4. Carefully remove the connecting rod cap.
5. Measure the width of the smashed plastic gauging material at its widest section
by using a scale printed on the plastic gauging material bag.
Standard value: 0.02 - 0.04 mm (0.0008 - 0.0016 inch)
Limit: 0.1 mm (0.003 inch)
Fig. 137: Checking Crankshaft Pin Oil Clearance

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2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

CRANKSHAFT AND CYLINDER BLOCKREMOVAL AND INSTALLATION
CAUTION: Do not remove the block heater unless it is damaged,
because it cannot be re-used once it is removed.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 138: Removing/Installing Crankshaft And Cylinder Block

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REQUIRED SPECIAL TOOL:
2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

MD998718: Crankshaft Rear Oil Seal Installer
INSTALLATION SERVICE POINTS >>A<< BLOCK HEATER INSTALLATION Within 30° of the center, install the block heater as shown in Fi
g.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 139: Installing Block Heater

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>>B<< KNOCK SENSOR BRACKET INSTALLATION Check that the bracket is in proper contact with the cylinder block boss and tighten
to the specified torque in the order shown.
Tightening torque: 28+/-2 N.m (21+/-1 ft-lb)
Fig. 140: Installing Knock Sensor Bracket

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>>C<< CRANKSHAFT BEARING INSTALLATION
2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor