MITSUBISHI ENDEAVOR 2004 Service Repair Manual

Fig. 11: Identifying Gear Shaf
t
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DISASSEMBLY AND ASSEMBLY Fig. 12: Disassembling/Assembling Sunroof Assembly

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2004 Mitsubishi Endeavor LS
2004 BODY & ACCESSORIES Sunroof Assembly - Endeavor

MITSUBISHI
3.8L V6 - SOHC - Endeavor & Galant
MANUFACTURER'S SUGGESTED SCHEDULED MAINTENANCE Manufacturer recommends the belt be replaced every 60,000 miles except in
California, Massachusetts and Vermont. In California, Massachusetts and Vermont,
timing belt replacement is recommended, but not required, at 60,000 miles. In these
states, replace timing belt at 105,000 miles, unless previously changed. REMOVAL & INSTALLATION TIMING BELT Removal 1. On Galant, remove engine cover. On all models, remove skid plate and under
cover. Remove accessory drive belts. Using Pulley Holder (MB991800) and
Pins "B" (MB001802), remove crankshaft pulley.
2. Disconnect harness connectors on connector bracket. See Fig. 1
or Fig. 2
.
Remove connector bracket. Remove engine mount support bracket. Remove
both upper timing belt covers.
3. Remove tensioner pulley and tensioner bracket. Remove crankshaft position
sensor harness clamp. Remove lower timing belt cover. Remove front engine
mount and front engine mount bracket.
4. Turn crankshaft clockwise to align camshaft and crankshaft timing marks. See
Fig. 3
. If timing belt is to be reused, place arrow on belt to indicate direction
of belt rotation.
5. Loosen belt tensioner
pulle
y center bolt. Remove timin
g belt. Remove timin
g CAUTION: This application is an interference engine. Do not
rotate camshaft or crankshaft when timing belt is
removed, or engine damage may occur.
CAUTION: Always turn crankshaft in clockwise direction (as
viewed from front of engine).

2004 Mitsubishi Endeavor Limited MITSUBISHI 3.8L V6 - SOHC - Endeavor & Galant


2004 Mitsubishi Endeavor Limited MITSUBISHI 3.8L V6 - SOHC - Endeavor & Galant

belt auto-tensioner.
Fig. 1: Exploded View Of Timing Belt Components (Endeavor)

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2004 Mitsubishi Endeavor Limited MITSUBISHI 3.8L V6 - SOHC - Endeavor & Galant

Fig. 2: Exploded View Of Timing Belt Components (Galant)

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2004 Mitsubishi Endeavor Limited MITSUBISHI 3.8L V6 - SOHC - Endeavor & Galant

Fig. 3: Aligning Timing Marks
2004 Mitsubishi Endeavor Limited MITSUBISHI 3.8L V6 - SOHC - Endeavor & Galant

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA
.
Inspection 1. Inspect timing belt for wear on edges of drive teeth. Inspect belt for signs of oil
contamination, cracks, separation, worn or missing teeth, or hardened back
surface. Replace belt if worn, damaged or contaminated. Inspect belt tensioner
pulley for smooth rotation. Replace if defective.
2. Check timing belt auto-tensioner for leaks. Check for wear or damage at end of
rod. Hold timing belt auto-tensioner upright. Measure rod protrusion above
edge of housing. See Fig. 4
. Apply 22-44 lbs. (98-196 N) of force to end of
rod. If auto tensioner rod moves more than 0.39" (1 mm), replace the auto-
tensioner.
Fig. 4: Checking Timing Belt Auto
-Tensioner Movement

2004 Mitsubishi Endeavor Limited MITSUBISHI 3.8L V6 - SOHC - Endeavor & Galant

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA
.
Installation 1. Place auto-tensioner in soft-jawed vise to SLOWLY compress the push rod. If
there is a plug at the base of the auto-tensioner body, place flat washer around
plug so it will not contact vise jaw.
2. Slowly compress auto-tensioner push rod until holes in push rod and auto-
tensioner housing are aligned. Insert a locking pin into the alignment holes.
Install auto-tensioner on engine.
3. Ensure all timing marks are still aligned. See Fig. 3
. Install timing belt on
crankshaft sprocket, idler pulley, left bank camshaft sprocket, water pump
pulley, right bank camshaft sprocket, and tensioner pulley. Take all slack out o
f
timing belt.
4. Loosen the tensioner pulley center bolt. Rotate tensioner pulley against timing
belt. Temporarily tighten tensioner pulley center bolt. Turn crankshaft 1/4 turn
counterclockwise. Turn crankshaft 1/4 turn clockwise. Ensure all timing belt
marks are still aligned.
5. Loosen tensioner pulley center bolt. Position tensioner pin holes at bottom of
tensioner. Install Adapter (MD998767) on tensioner pulley. See Fig. 5
. Using
torque wrench, apply 39 INCH lbs. (4.4 N.m) of torque (counterclockwise
direction) to tensioner pulley. Tighten tensioner center bolt to specification
while holding tensioner pulley stationary. See TORQUE
SPECIFICATIONS
.
6. Remove locking pin from auto-tensioner. Turn crankshaft 2 revolutions
clockwise and align all timing marks. DO NOT rotate counterclockwise.
7. Wait for at least 5 minutes, then check auto-tensioner push rod protrusion. To
check push rod protrusion, measure clearance between body of auto-tensioner
and bottom of tensioner pulley bracket arm. Clearance should be 0.19-
0.24" (4.8-6.0 mm). If protrusion is not correct, repeat timing belt tensioning
procedure. CAUTION: Never compress the auto-tensioner too fast, or
the push rod will be damaged.

2004 Mitsubishi Endeavor Limited MITSUBISHI 3.8L V6 - SOHC - Endeavor & Galant

8. Install timing belt covers. Install crankshaft pulley. Using Pulley Holder
(MB991800) and Pins "B" (MB001802), tighten crankshaft pulley bolt to
specification. See TORQUE SPECIFICATIONS
. To complete installation,
reverse removal procedure.
Fig. 5: Adjusting Timing Belt Tension

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TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Application
Ft. Lbs. (N.m)
Auto-Tensioner Bolt
15-19 (20-26)
Camshaft Sprocket Bolt
58-72 (78-98)
Crankshaft Pulley Bolt
(1) 134-140 (180-

2004 Mitsubishi Endeavor Limited MITSUBISHI 3.8L V6 - SOHC - Endeavor & Galant

190)
Engine Mount Bracket-To-Engine Bolt
31-37 (42-48)
Timing Belt Idler Pulley Bolt
30-36 (39-49)
Timing Belt Tensioner Arm Pivot Bolt
26-40 (34-54)
Timing Belt Tensioner Center Bolt
32-40 (42-54)
INCH Lbs. (N.m)
Timing Belt Cover Bolt
97 (11)
(1)
Apply engine oil to bolt threads before installation.

2004 Mitsubishi Endeavor Limited MITSUBISHI 3.8L V6 - SOHC - Endeavor & Galant

2004 BRAKES
Traction Control System (TCL) - Endeavor
GENERAL DESCRIPTION The traction control system (TCL) controls engine output to prevent the wheel spin
of the drive wheels (front wheels) for improved stability.
The TCL system is available as individual optional equipment for FWD and as set
optional equipment with ASC for AWD. For the details about the ASC, refer to
TRACTION CONTROL/ACTIVE SKID
.
CONSTRUCTION DIAGRAM Fig. 1: Identifying Traction Control System

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y of MITSUBISHI MOTOR SALES OF AMERICA
.

2004 Mitsubishi Endeavor LS
2004 BRAKES Traction Control System (TCL) - Endeavor


2004 Mitsubishi Endeavor LS
2004 BRAKES Traction Control System (TCL) - Endeavor