MITSUBISHI ENDEAVOR 2004 Service Repair Manual

Fig. 91: Aligning Timing Marks On Camshaft Sprockets

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2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor

2. Install the timing belt by the following procedure so that there is no deflection
in the timing belt between each sprocket and pulley.
1. Crankshaft sprocket
2. Idler pulley
3. Camshaft sprocket (Left bank)
4. Water pump pulley
5. Camshaft sprocket (Right bank)
6. Tensioner pulley
3. Turn the camshaft sprocket (Right bank) counterclockwise until the tension
side of the timing belt is firmly stretched. Check all the timing marks again.
4. Use special tool MD998767 to push the tensioner pulley into the timing belt,
then temporarily tighten the center bolt.
Fi
g. 92: Pushin
g Tensioner Pulle
y Into Timin
g Bel
t

2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor

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.
5. Use special tool MD998769 to turn the crankshaft 1/4 turn counterclockwise,
then turn it again clockwise until the timing marks are aligned.
Fig. 93: Aligning Timing Marks

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6. Loosen the center bolt of the tensioner pulley. Use special tool MD998767 and
a torque wrench to apply the tension torque to the timing belt as shown in the
illustration. Then tighten the center bolt to the specified torque.
Standard value: 4.4 N.m (39 in-lb) < Timing belt tension torque >
CAUTION: When tightening the center bolt, be careful that
the tensioner pulley does not turn with the bolt.

2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor

Tightening torque: 48 +/- 6 N.m (36 +/- 4 ft-lb)
Fig. 94: Loosening Center Bolt Of Tensioner Pulley

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7. Remove the setting pin that has been inserted into the auto-tensioner.

2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor

Fig. 95: Removing Setting Pin That Has Been Inserted Into Auto
-
Tensioner

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8. Turn the crankshaft clockwise twice to align the timing marks.
9. Wait for at least five minutes, then check that the auto-tensioner pushrod
extends within the standard value range.
Standard value (A): 4.8 - 6.0 mm (0.19 - 0.24 inch)

2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor

Fig. 96: Checking Auto
-Tensioner Pushrod Extends Within Standard
Value Range

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10. If not, repeat the operation in steps 1 to 8 above.
11. Check a
gain that the timin
g marks of the s
prockets are ali
gned.

2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor

>>C<< CRANKSHAFT PULLEY INSTALLATIONUse special tools MB991800 and MB991802 to install the crankshaft pulley.
Fig. 97: Installing Crankshaft Pulley

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INSPECTION AUTO-TENSIONER ADJUSTER CHECK 1. Check for oil leak from seal, and replace it if leak is detected.
2. Check for wear or dama
ge at the to
p of the rod. Re
place it, if re
quired.

2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor

Fig. 98: Checking Rod

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3. While holding the auto-tensioner with your hand, press the end of the pushrod
against a metal surface (such as the cylinder block) with a force of 98 - 196 N
(22 - 44 pound) and measure how far the pushrod is pushed in.
Standard value: Within 1 mm (0.04 inch)
A: Length when no force is applied
B: Length when force is applied
A - B: Movement in

2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor

Fig. 99: Pressing End Of Pushrod Against Metal Surface

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4. If the measured value is out of the standard value, replace the auto-tensioner
adjuster.
CYLINDER BLOCK HEATER UNIT REMOVAL AND INSTALLATION
2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor

Fig. 100: Removing/Installing Cylinder Block Heater Unit Component

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REMOVAL SERVICE POINT << A >> CYLINDER BLOCK HEATER UNIT REMOVAL Remove the cylinder block heater unit by using a flat-tipped screwdriver. INSTALLATION SERVICE POINT >>A<< CYLINDER BLOCK HEATER UNIT INSTALLATION 1. Install the cylinder block heater unit to the cylinder block within the range as
shown.
2. Tighten the cylinder block heater unit mounting bolt to the specified torque.
Ti
ghtenin
g tor
que: 2.6 +/- 0.2 N.m (23 +
/- 2 i
n-lb)

2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor