Intake MITSUBISHI ENDEAVOR 2004 Service User Guide

Fig. 75: Removing Spring Using Special Tool MD998772

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
INSTALLATION SERVICE POINTS >>A<< VALVE STEM SEAL INSTALLATION 1. Install the valve spring seat. NOTE: Tag removed valves, springs and other components, noting
their cylinder numbers and locations to facilitate
reassembly. Store these components safely.
CAUTION:
Valve stem seals for intake valves and for
exhaust valves are different. Be sure to
install the correct ones.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 76: Identifying Intake And Exhaust Valve Seating

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Using special tool MD998774, install a new stem seal to the valve guide.
Valve stem seal identification color
Identification color
Intake: GRAY
Exhaust: GRAY GREEN
CAUTION: Always use the special tool to install the valve
stem seal. Improperly installed valve stem seals
may leak oil.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 83: Checking Valve Face And Margin

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. If the margin exceeds the service minimum limit, replace the valve.
Standard value:
< Intake > 1.0 mm (0.04 inch)
< Exhaust > 1.2 mm (0.05 inch)
Minimum limit:
< Intake > 0.5 mm (0.02 inch)
< Exhaust > 0.7 mm (0.03 inch)
3. Measure the valve's total length. If the measurement is less than specified,
replace the valve.
Standard value:

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

< Intake > 110.30 mm (4.343 inches)
< Exhaust > 112.11 mm (4.414 inches)
Minimum limit:
< Intake > 109.80 mm (4.323 inches)
< Exhaust > 111.61 mm (4.394 inches)
Fig. 84: Measuring Valve Length

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VALVE SPRINGS 1. Measure the free height of the spring and, if it is smaller than the minimum
limit, replace the spring.
Standard value: 51.0 mm (2.01 inches)
Minimum limit: 50.0 mm (1.97 inches)
2. Measure the squareness of the spring and, if the limit is exceeded, replace the
s
prin
g.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Measure the clearance between the valve guide and valve stem. If the limit is
exceeded, replace the valve guide, valve, or both.
Standard value:
< Intake > 0.02 - 0.05 mm (0.0008 - 0.0019 inch)
< Exhaust > 0.04 - 0.06 mm (0.0016 - 0.0023 inch)
Limit:
< Intake > 0.10 mm (0.003 inch)
< Exhaust > 0.15 mm (0.005 inch)
Fig. 86: Measuring Clearance Between Valve Stem And Vale Guide

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VALVE SEAT Assemble the valve, then measure the valve stem
projection between the end of the

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

valve stem and the spring seating surface. If the measurement exceeds the specified
limit, replace the valve seat.
Standard value:
< Intake > 48.30 mm (1.902 inches)
< Exhaust > 51.71 mm (2.036 inches)
Limit:
< Intake > 48.80 mm (1.921 inches)
< Exhaust > 52.21 mm (2.056 inches)
Fig. 87: Measuring Valve Stem Projection

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

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

Fig. 57: Identifying Installation Position Of Valve Spring Compressor Special Tool

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
INSTALLATION SERVICE POINTS >>A<< VALVE STEM SEAL INSTALLATION 1. Apply a small amount of engine oil to the valve stem seal.
2. Use special tool MD998774 to fill a new valve stem seal in the valve guide
using the valve stem area as a guide. NOTE: Installation position of valve sprin
g compressor special tool
(MD998772) is different between exhaust side and intake
side.
CAUTION:
Valve stem seals cannot be reused. Special tool MD998774 must be used to
install the valve stem seal. Improper
installation could result in oil leaking past the
valve guide.

2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor

Fig. 10: Removing And Installing Crankshaft Position Sensor

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KNOCK SENSOR REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation
Intake Manifold Removal and Installation (Refer to REMOVAL AND INSTALLATION
).

2004 Mitsubishi Endeavor Limited 2004 ENGINE Ignition System - Endeavor

2004 ENGINE
Intake And Exhaust - Endeavor
GENERAL DESCRIPTION The exhaust pipe is divided into three parts. INTAKE AND EXHAUST DIAGNOSIS INTRODUCTION Intake leaks usually create driveability issues that are not obviously related to the
intake system. Exhaust leaks or abnormal noise is caused by cracks, gaskets and
fittings, or by exhaust pipe or muffler damage due to impacts during travel. The
exhaust leaks from these sections and causes the exhaust noise to increase. There
may be cases when the system contacts the body and vibration noise is generated. TROUBLESHOOTING STRATEGY Use these steps to plan your diagnostic strategy. If you follow them carefully, you
will be sure that you have exhausted most of the possible ways to find an intake or
exhaust system fault.
1. Gather information from the customer.
2. Verify that the condition described by the customer exists.
3. Find the malfunction by following SYMPTOM CHART
.
4. Verify malfunction is eliminated.
SYMPTOM CHART INTAKE AND EXHAUST SYMPTOM CHART SYMPTOM
INSPECTION PROCEDURE
Exhaust Leakage
INSPECTION PROCEDURE 1:
EXHAUST LEAKAGE
.
Abnormal Noise
INSPECTION PROCEDURE 2:
ABNORMAL NOISE
.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Intake And Exhaust - Endeavor


2004 Mitsubishi Endeavor Limited 2004 ENGINE Intake And Exhaust - Endeavor