cover MITSUBISHI ENDEAVOR 2004 Service Service Manual

(Ignition Timing Check)

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3. Set up a timing light.
4. Start the engine and run it at idle.
5. Check that the idle speed is approximately 680 r/min.
6. Select scan tool MB991958 actuator test "item number 17".
7. Check that basic ignition timing is within the standard value.
Standard value: 5° BTDC +/-3°
8. If the basic ignition timing is not within the standard value, check the
following items:
Diagnostic output Timing belt cover and crankshaft position sensor installation conditions Crankshaft sensing blade condition
9. Press the clear key on scan tool MB991958 (select forced drive stop mode),
and cancel the actuator test.
10. Check that the actual ignition timing is at the standard value.
Standard value: Approximately 10° BTDC
CURB IDLE SPEED CHECK Required Special Tool:
CAUTION: If the actuator test is not canceled, the forced
drive will continue for 27 minutes. Driving in this
state could lead to engine failure.
NOTE: Ignition timing fluctuates about+/-7° Before T op Dead
Center, even under normal operating condition.
NOTE: It is automatically further advanced by about 5° to 10°
Before Top Dead Center at higher altitudes.

2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor

Fig. 21: Disconnecting Crankshaft Position Sensor Connector

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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

2. Cover the end of a flat-tipped screwdriver with a shop towel and insert into the
notched section of the oil seal, and pry out the oil seal to remove it.
Fig. 46: Removing Camshaft Oil Seal

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INSTALLATION SERVICE POINTS >>A<< CAMSHAFT OIL SEAL INSTALLATION 1. A
pply en
gine oil to the camshaft oil seal li
p.
cylinder head.

2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor

Fig. 54: Removing Camshaft Oil Seal

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2. Cover the end of a flat-tipped screwdriver with a shop towel and insert into the
notched section of the oil seal, and pry out the oil seal to remove it.
<< D >> VALVE SPRING RETAINER LOCK REMOVAL Use special tool MD998772 to compress the valve spring, and remove the valve
sprin
g retainer locks.
cylinder head.
CAUTION: When removing valve spring retainer locks, leave the
piston of each cylinder in the TDC (Top Dead Center)
position. The valve may fall into the cylinder if the
piston is not properly in the TDC position.

2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor

4. Install the auto-tensioner to the engine.
>>B<< TIMING BELT INSTALLATION 1. Align the timing marks on the camshaft sprockets with those on the rocker
cover and the timing mark on the crankshaft sprocket with that on the engine
block as shown in the illustration.
CAUTION: Do not remove the setting pin from the auto-
tensioner.
CAUTION: The camshaft sprocket (right bank) can turn
easily due to the spring force applied, so be
careful not to get your fingers caught.

2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor

Fig. 37: Identifying PTJ Boot Dimension

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INSPECTION
Check the drive shaft for damage, bending or corrosion. Check the inner shaft for damage, bending or corrosion. Check the drive shaft spline part for wear or damage. Check the inner shaft spline part for wear or damage. Check the spider assembly for roller rotation, wear or corrosion. Check the groove inside PTJ case for wear or corrosion. Check the boots for deterioration, damage or cracking. Check the center bearing for seizure, discoloration or roughness of rolling
surface. Check the dust cover for damage or deterioration.
DISASSEMBLY AND REASSEMBLY
2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLES Front Axle Hub & Axle Shafts - Endeavor

AXLE SHAFTS Removal & Installation For removal and installation of axle shafts, see Fig. 4
. NOTE: Before removing axle shaft, remove front cover and side
under cover, and drain automatic transmission and transfer
fluids. Then remove front exhaust pipe and transfer heat
protector.

2004 Mitsubishi Endeavor LS
2004 DRIVE AXLES Axle Shafts - Front - Endeavor

Fig. 11: Adjusting Camber

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3. Tighten the nuts to 305 +/- 25 N.m (225 +/- 18 ft-lb).
4. Recheck the camber.
LOWER ARM BALL JOINT END PLAY CHECK 1. Raise the vehicle.
2. Move the lower arm up and down with your hands to check for an excessive
play in the axial direction of the ball joint. If there is an excessive play, replace
the lower arm assembly. BALL JOINT DUST COVER CHECK 1. Press the dust cover with your finger to check that there are no cracks or
damage in the dust cover.
2. If the dust cover is cracked or damaged, replace the lower arm assembly. STRUT ASSEMBLY REMOVAL AND INSTALLATION
NOTE: If the dust cover is cracked or damaged, it is possible
that there may also be damage to the ball joint.

2004 Mitsubishi Endeavor LS 2004 SUSPENSION Front - Endeavor

1. After shaking the ball joint stud several times, use special tool MB991006 to
measure the breakaway torque of the ball joint.
Fig. 23: Measuring Ball Joint Breakaway Torque

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Standard value: 2.5 - 6.1 N.m (22 - 54 in-lb)
2. If the measured value is not within the standard value, or if the ball joint is
difficult to turn or does not turn smoothly, replace the lower arm assembly.
LOWER ARM BALL JOINT DUST COVER CHECK 1. Check the dust cover for cracks or damage by pushing it with your finger.
2. If the dust cover is cracked or damaged, replace the lower arm. BALL JOINT DUST COVER REPLACEMENT
NOTE: Cracks or damage to the dust cover may cause damage
to the ball joint. When it is damaged during service
work, replace the dust cover.

2004 Mitsubishi Endeavor LS 2004 SUSPENSION Front - Endeavor

Required Special Tool
:
MB990800: Ball Joint Remover and Installer
If the dust cover is damaged accidentally during service work, replace the dust
cover as follows:
1. Remove the dust cover.
2. Apply the multipurpose grease SAE J310, NLGI No. 2 or equivalent to the lip
and the inside of a new dust cover.
Grease amount for the inside the dust cover (reference): 13 +/- 0.5 g (0.45
+/- 0.02 oz.)
3. Using special tool MB990800, drive in the dust cover until it is fully seated.
Fig. 24: Installing Dust Cover

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2004 Mitsubishi Endeavor LS 2004 SUSPENSION Front - Endeavor