MITSUBISHI ENDEAVOR 2004 Service Repair Manual

the vacuum gauge reading.
Idle speed: 680+/-100 r/min
Minimum limit: 60 kPa (18 in Hg)
LASH ADJUSTER CHECK If an abnormal noise (chattering noise) suspected to be caused by malfunction of the
lash adjuster is produced immediately after starting the engine and does not
disappear, perform the following check.
1. Start the engine.
2. Check if the abnormal noise produced immediately after starting the engine,
changes with the change in the engine speed.
If the abnormal noise is not produced immediately after starting the engine or it
does not change with the engine speed, the lash adjuster is not the cause for the
noise.
Therefore, investigate other causes. The abnormal noise is probably caused by
some other parts than the engine proper if it does not change with the engine
speed. (In this case, the lash adjuster is in good condition.)NOTE: An abnormal noise due to malfunction of the lash adjuster
is produced immediately after starting the engine and
changes with the engine speed, irrespective of the engine
load. If, the abnormal noise is not produced immediately
after starting the engine or does not change with the engine
speed, or it changes with the engine load, the lash adjuster
is not the cause for the abnormal noise.
NOTE: When the lash adjuster is malfunctioning, the abnormal
noise is rarely eliminated by continuing the warming-up of
the engine at idle speed.
However, the abnormal noise may disappear only when
seizure is caused by oil sludge in the engine whose oil is
not maintained properly.
2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor

3. With the engine idling, change the engine load (shift from N to D range, for
example) to make sure that there is no change in the level of abnormal noise.
If there is a change in the level of abnormal noise, suspect a tapping noise due
to worn crankshaft bearing or connecting rod bearing (In this case, the lash
adjuster is in good condition.).
4. After completion of warm-up, run the engine at idle to check for abnormal
noise.
If the noise is reduced or disappears, clean the lash adjuster (Refer to
ROCKER ARMS AND CAMSHAFT
). As it is suspected that the noise is
due to seizure of the lash adjuster. If there is no change in the level of the
abnormal noise, proceed to step 5.
5. Run the engine to bleed the lash adjuster system (Refer to LASH ADJUSTER
CHECK
.).
6. If the abnormal noise does not disappear after air bleeding operation, clean the
lash adjuster (Refer to ROCKER ARMS AND CAMSHAFT
).
Bleeding lash adjuster system 1. Check engine oil and add or change oil if required. NOTE: Parkin
g the vehicle on a
grade for a lon
g time ma
y decrease
oil in the lash adjuster, causing air to enter the high
pressure chamber when starting the engine.
NOTE: After parking for many hours, oil may run out from the oil
passage and take time before oil is supplied to the lash
adjuster, causing air to enter the high pressure chamber.
NOTE: In the above cases, abnormal noise can be eliminated by
bleeding the lash adjuster system.
NOTE: If the engine oil level is low, air is sucked from the oil

2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor

Fig. 25: Checking Engine Oil Level

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
screen, causing air to enter the oil passage.
NOTE: If the engine oil level is higher than specification, oil
may be stirred by the crankshaft, causing oil to be
mixed with a large quantity of air.
NOTE: If oil is deteriorated, air is not easily separated from oil,
increasing the quantity of air contained in oil.

2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor

Fig. 26: Identifying High Pressure Chamber

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Idle the engine for one to three minutes to warm it up.
3. Repeat the operation pattern, shown in left figure, at no load to check for
abnormal noise. (Usually the abnormal noise is eliminated after repetition of
the ope
ration 1
0 to 30 tim
es.
If, howeve
r, no change is obse
rved
in
the leve
l of
NOTE: If air mixed with oil enters the high pressure chamber
inside the lash adjuster from the above causes, air in
the high pressure chamber is compressed excessively
while the valve is opened, resulting in an abnormal
noise when the valve closes. This is the same
phenomenon as that observed when the valve
clearance has become excessive. The lash adjuster can
resume normal function when air entered the lash
adjuster is removed.

2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor

abnormal noise after repeating the operation more than 30 times, suspect that
the abnormal noise is due to some other factors.)
Fig. 27: Air Bleeding Operation Pattern

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
4. After elimination of abnormal noise, repeat the operation shown in left figure
five more times.
5. Run the engine at idle for one to three minutes to make sure that the abnormal
noise has been eliminated.
ENGINE ASSEMBLY REMOVAL AND INSTALLATION
CAUTION: *: indicates part which should be temporarily
tightened, and then fully tightened with the engine

2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor

Fig. 28: Removing/Installing Engine (1 Of 3)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
weight applied on the vehicle body.

2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor

Fig. 29: Removing/Installing Engine (2 Of 3)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor

Fig. 30: Removing/Installing Engine (3 Of 3)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Required Special Tools:
MB991454: Engine Hanger Balancer MB991895: Engine Hanger MB991928: En
gine Han
ger

2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor

REMOVAL SERVICE POINTS << A >> FUEL MAIN PIPE DISCONNECTION 1. Remove the stopper.
Fig. 31: Removing Stopper

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2. Remove the fuel main pipe while the retainer is pulled up.
CAUTION: Do not bend the resin fuel high-pressure hose.
NOTE: If the retainer is removed, install it after removing the fuel
main pipe.
2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor

Fig. 32: Pulling Retainer

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
<< B >> RESERVIOR ASSEMBLY REMOVAL Remove the reservoir assembly from the body with the hose attached. << C >>A/C COMPRESSOR ASSEMBLY REMOVAL Remove the compressor from the compressor bracket with the hose still attached. NOTE: Place the removed reservoir assembly in a place where it
will not be a hindrance when removing and installing the
engine assembly, and secure it with a cord or wire.
NOTE: Place the removed A/C compressor where it will not be a
hindrance when removing and installing the engine
2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor