fuel MITSUBISHI ENDEAVOR 2004 Service Owner's Manual

Fig. 66: Eliminating Diesel Fuel From The Pressure Chamber

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
5. Place the lash adjuster in container B. Then, gently push down the internal steel
ball using a wire [0.5 mm (0.020 inch) in diameter] or special tool MD998442
and move the plunger through five to ten strokes until it slides smoothly. This
o
peration will clean the lash ad
juster's
pressure chamber.
CAUTION: The steel ball spring is extremely weak, so the
lash adjuster's functionality may be lost if the air
bleed wire is pushed in hard.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 67: Using Special Tool MD998442

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
6. Remove the lash adjuster from the container. Then, push down the steel ball
gentl
y and
push the
plun
ger to eliminate diesel fuel from the
pressure chamber.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 68: Pushing Down The Steel Ball And Plunger To Eliminate Diesel

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
7. Place the lash adjuster in container C. Then, gently push down the internal steel
ball using a wire [0.5 mm (0.020 inch) in diameter] or special tool MD998442.
CAUTION: Do not use container C for cleanin
g. If cleanin
g is
performed in container C, foreign matter could
enter the pressure chamber when the chamber is
filled with diesel fuel.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 69: Placing Lash Adjuster In Container C

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
8. Stand the lash adjuster with its plunger at the top, then push the plunger
downward firmly until it moves through its greatest possible stroke. Return the
plunger slowly, then release the steel ball and allow the pressure chamber to
fill with diesel fuel.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 70: Pushing Plunger Downward To Fill Fuel

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
9. Remove the lash adjuster from the container, then stand the lash adjuster with
its plunger at the top. Push the plunger firmly and check that it does not move.
NOTE: If the lash adjuster contracts or moves, repeat steps 7
through 9 again to fill it with diesel fuel completely.
Replace the lash adjuster if it still contracts or moves
after performing these steps.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 71: Removing Lash Adjuster From The Container And Checking Move

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
10. Stand the lash adjuster upright to prevent diesel fuel from spilling out. Do not
allow the lash adjuster to become contaminated by dirt or other foreign matter.
Install the lash adjuster onto the engine as soon as possible.
CYLINDER HEAD AND VALVES REMOVAL AND INSTALLATION
2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA
.
3. Check the basic ignition timing.
Standard value: 5° BTDC+/-3°
4. Start the engine.
5. Run the engine at idle for 2 minutes.
6. Check the idle speed. Select item number 22 and take a reading of the idle
speed.
Curb idle speed: 680+/-100 r/min
7. If the idle speed is outside the standard value, refer to MULTIPORT FUEL
INJECTION (MFI) DIAGNOSIS
.
IDLE MIXTURE CHECK Required Special Tool:
MB991958: Scan Tool (MUT-III Sub Assembly)
MB991824: V.C.I. MB991827: MUT-III USB Cable MB991910: MUT-III Main Harness A
1. Before checks set the vehicle in the following condition:
Engine coolant temperature: 80 - 95°C (176 - 203°F) Lights and all accessories: OFF Transaxle: P range
NOTE: The idle speed is controlled automaticall
y by the idle air
control system.
NOTE: Vehicles for Canada, the headlight, taillight, etc. remain
lit even when the lighting switch is in "OFF" position
but this is no problem for checks.

2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor

Mixture Check)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3. Check that the basic ignition timing is within the standard value.
Standard value: 5° BTDC+/-3°
4. Start the engine and increase the engine speed to 2,500 r/min for 2 minutes.
5. Set the CO, HC tester.
6. Check the CO contents and the HC contents at idle.
Standard value:
CO contents: 0.5% or less
HC contents: 100 ppm or less
7. If the CO and HC contents do not remain inside the standard value, check the
following items:
Diagnostic output Closed-loop control (When the closed-loop control is carried out normally, the
output signal of the heated oxygen sensor changes between 0 - 400 mV and
600 - 1,000 mV at idle.) Fuel pressures Injector Ignition coil, spark plug EGR system and EGR valve leak Evaporative emission system Compression pressure
COMPRESSION PRESSURE CHECK Re
quired S
pecial Tool
:
NOTE: Replace the catalytic converter when the CO and HC
contents do not remain inside the standard value, even
though the result of the inspection is normal for all items.
2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor

MB991958: Scan Tool (MUT-III Sub Assembly)
MB991824: V.C.I. MB991827: MUT-III USB Cable MB991910: MUT-III Main Harness A
1. Before checks set the vehicle in the following condition:
Engine coolant temperature: 80 - 95°C (176 - 203°F) Lights and all accessories: OFF Transaxle: P range
2. Remove all of the ignition coils and spark plugs.
3. Disconnect the crankshaft position sensor connector.
NOTE: Vehicles for Canada, the headlight, taillight, etc. remain
lit even when the lighting switch is in "OFF" position
but this is no problem for checks.
NOTE: Doing this will prevent the engine control module from
carrying out ignition and fuel injection.

2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor

Fig. 21: Disconnecting Crankshaft Position Sensor Connector

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
4. Cover the spark plug hole with a shop towel etc., during cranking. After the
engine has been cranked, check for foreign material adhering to the shop towel.
5. Set compression gauge to one of the spark plug holes.
WARNING:Keep your distance from the spark plug hole
when cranking. Oil, fuel, etc., may spray out
from the spark plug hole and may cause serious
injury.

2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor