Figure 49 MITSUBISHI ENDEAVOR 2004 Service Repair Manual

Fig. 67: Installing Wave Spring Onto Low
-Reverse Brake Piston

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
9. Install the six brake discs, five brake plates and snap ring as shown in the
figure.
10. Install special tool MB991632 on the brake disc.
11. Install the reaction plate and the used snap ring.
12. Move special tool MB991632 to measure the end play of reaction plate. Then
replace the snap ring installed in step 11 to adjust the end play to standard
value.
CAUTION: If necessary, take the measurements in steps 9 to
18 after replacing the pressure plate, brake plate
and brake disc.
NOTE: Do not install the pressure plate at this time.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Standard value: 0 - 0.16 mm (0 - 0.0063 inch)
Fig. 68: Measuring End Play Of Reaction Plate

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
13. Install the brake discs and brake plates as shown in the figure.
14. Place special tool MB991632 on top of the brake disc in place of the pressure
plate.
15. Install the return s
prin
g, second brake
piston and sna
p rin
g.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

2004 ELECTRICAL
Battery - Endeavor
BATTERY ON-VEHICLE SERVICE BATTERY CHECK
BATTERY VISUAL INSPECTION (1) 1. Ensure that the battery electrolyte level is between A and B shown in the
figure. Add if the level is lower than the specified range.
2. Use a hydrometer and temperature gauge to check the specific gravity of the
electrolyte.
Standard value:
1.220 - 1.290 [at 20°C (68°F)]
The specific gravity of electrolyte depends on its temperature. Use the formula
below to determine the proper value.
Conversion on centigrade
D20 =(t - 20) x 0.0007 + Dt
Conversion on Fahrenheit
D20 =(t - 68) x 0.0007 + Dt
D20 : Specific gravity as if electrolyte temperature is 20°C (68°F)
WARNING:Battery posts, terminals and related accessories
contain lead and lead compounds. WASH HANDS
AFTER HANDLING.

2004 Mitsubishi Endeavor Limited 2004 ELECTRICAL Battery - Endeavor


2004 Mitsubishi Endeavor Limited 2004 ELECTRICAL Battery - Endeavor

COMPONENT LOCATION GRAPHICS Fig. 1: Control Units (1 Of 15)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
S087
side o
f
engine
compartment.
See Fig. 84 .
S088
In dash
harness, left
end of dash.
See Fig. 81
.
NOTE: Figures may show multiple component locations. Refer to
appropriate table for proper figure references.
2004 Mitsubishi Endeavor LS
2004 MITSUBISHI Endeavor

Fig. 80: Using Special Tool MD998772 For Installing Retainer Lock

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
>>D<< CYLINDER HEAD BOLT INSTALLATION 1. Tighten the bolts in the illustrated sequence two or three steps.
Tightening torque: 108+/-5 N.m (80+/-4 ft-lb)
CAUTION: Attach the head bolt washer in the direction shown in
the figure.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 26: Identifying High Pressure Chamber

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Idle the engine for one to three minutes to warm it up.
3. Repeat the operation pattern, shown in left figure, at no load to check for
abnormal noise. (Usually the abnormal noise is eliminated after repetition of
the ope
ration 1
0 to 30 tim
es.
If, howeve
r, no change is obse
rved
in
the leve
l of
NOTE: If air mixed with oil enters the high pressure chamber
inside the lash adjuster from the above causes, air in
the high pressure chamber is compressed excessively
while the valve is opened, resulting in an abnormal
noise when the valve closes. This is the same
phenomenon as that observed when the valve
clearance has become excessive. The lash adjuster can
resume normal function when air entered the lash
adjuster is removed.

2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor

abnormal noise after repeating the operation more than 30 times, suspect that
the abnormal noise is due to some other factors.)
Fig. 27: Air Bleeding Operation Pattern

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
4. After elimination of abnormal noise, repeat the operation shown in left figure
five more times.
5. Run the engine at idle for one to three minutes to make sure that the abnormal
noise has been eliminated.
ENGINE ASSEMBLY REMOVAL AND INSTALLATION
CAUTION: *: indicates part which should be temporarily
tightened, and then fully tightened with the engine

2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor

1. Install the special tool MB991897 as shown in the figure.
Fig. 4: Installing Special Tool MB991897

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Turn the bolt and knob as necessary to make the jaws of special tool
MB991897 parallel, tighten the bolt by hand and confirm that the jaws are still
parallel.
3. Tighten the bolt with a wrench to disconnect the tie rod end and remove the
self lockin
g nut.
NOTE: When adjusting the jaws in parallel, make sure the knob
is in the position shown in the figure.

2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLES Front Axle Hub & Axle Shafts - Endeavor

1. Install special tool MB991897 as shown in the figure.
Fig. 16: Installing Special Tool MB991897

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2. Turn the bolt and knob as necessary to make the jaws of special tool
MB991897 parallel, tighten the bolt by hand and confirm that the jaws are still
parallel.
3. Tighten the bolt with a wrench to disconnect the tie rod end and remove the
self lockin
g nut.
NOTE: When adjusting the jaws in parallel, make sure the knob
is in the position shown in the figure.

2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLES Front Axle Hub & Axle Shafts - Endeavor

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA
.
Required Special Tool:
MB991897: Ball Joint Remover
REMOVAL SERVICE POINT <> TIE ROD END AND KNUCKLE DISCONNECTION 1. Install special tool MB991897 as shown in the figure.
CAUTION:
Do not remove the nut from ball joint. Loosen it
and use special tool MB991897 to avoid possible
damage to ball joint threads. Hang special tool MB991897 with a cord to
prevent it from falling.

2004 Mitsubishi Endeavor LS 2004 SUSPENSION Front - Endeavor