engine gasket MITSUBISHI ENDEAVOR 2004 Service Repair Manual

Fig. 2: Checking Engine Oil Level

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
ENGINE OIL REPLACEMENT 1. Start the engine and allow it to warm up until the temperature of the coolant
reaches 80 - 90°C (176 - 194°F).
2. Remove the engine oil filler cap.
3. Remove the drain plug to drain oil.
4. Install a new drain plug gasket so that it faces in the direction shown in the
illustration, and then tighten the drain plug to the specified torque.
Tightening torque: 39 +/- 5 N.m (29 +/- 3 ft-lb)
WARNING:Use care as oil could be hot.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Lubrication - Endeavor

INSTALLATION SERVICE POINT>>A<< BOOST SENSOR INSTALLATION
>>B<< THROTTLE BODY GASKET INSTALLATION Install the throttle body gasket so that the tab is positioned as shown in the
illustration.
Fig. 8: Installing The Throttle Body Gasket

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
Do not strike or drop to the sensor. Never use a sensor that has been dropped.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

>>C<< EXHAUST GAS RECIRCULATION VALVE GASKET INSTALLATION Install the exhaust gas recirculation valve gasket so that the tab is positioned as
shown in the illustration.
Fig. 9: Installing The Exhaust Gas Recirculation Valve Gasket

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
>>D<< EXHAUST GAS RECIRCULATION PIPE GASKET INSTALLATION Install the exhaust gas recirculation pipe gasket so that the tab is positioned as
shown in the illustration.
2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 10: Installing The Exhaust Gas Recirculation Pipe Gasket

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
>>E<< EXHAUST GAS RECIRCULATION PIPE GASKET INSTALLATION Install the exhaust gas recirculation pipe gasket so that the tab is positioned as
shown in the illustration.
2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 11: Installing The Exhaust Gas Recirculation Pipe Gasket

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
>>F<< EXHAUST GAS RECIRCULATION PIPE (EXHAUST SIDE) INSTALLATION 1. Tighten temporarily the flare nut of exhaust gas recirculation pipe and the nut
shown in the illustration.
2. Tighten each the flare nuts of exhaust gas recirculation pipe and the nut shown
in the illustration, to the specified torque.
Tightening torque:
59+/-10 N.m (44+/-7 ft-lb) < FLARE NUT >
11+/-1 N.m (95+/-9 in-lb) < NUT >
CAUTION: Use care to prevent deforming the bellows of the
exhaust gas recirculation pipe.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

3. Insert the front end of the pipe into the water pump. >>B<< THERMOSTAT HOUSING GASKET INSTALLATION Install the thermostat housing gasket so that the tab is positioned as shown in the
illustration.
Fig. 47: Installing Thermostat Housing Gasket

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
>>C<< THERMOSTAT INSTALLATION 1. Check that the rubber ring is free from damage and seated correctly in the
thermostat flange.
2. Install the thermostat as shown in the illustration. The jiggle valve must be at
the to
p position.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA
.
2. Back off the bolts once and tighten them again to the specified torque in step 1.
INSPECTION CYLINDER HEAD 1. Check the cylinder head gasket surface for flatness by using a straightedge in
the directions of A through G shown in the illustration.
Standard value: 0.03 mm (0.0012 inch)
Limit: 0.2 mm (0.007 inch)
2. If the service limit is exceeded, correct to meet the specification.
Grinding limit: *0.2 mm (0.007 inch)
3. *If the service limit is exceeded, correct to meet the specification.
Cylinder head height (specification when new): 120 mm (4.7 inches)
2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

VALVE GUIDE REPLACEMENT PROCEDURE1. Remove the snap ring from the exhaust valve guide.
2. Using a press, remove the valve guide toward the cylinder head gasket surface.
Fig. 91: Identifying Valve Guide Replacement Procedure

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3. Re-bore the valve guide hole of the cylinder head so that it fits the press-fitted
oversize valve guide.
Valve Guide Hole Diameter:
CAUTION: Do not install a valve guide of the same size
again.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 97: Installing Outer/Inner Rotor

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
>>B<< OIL PUMP CASE ASSEMBLY INSTALLATION 1. Clean the gasket mating surfaces of oil pump case and cylinder block.
2. Apply a 3 mm (0.1 inch) diameter bead of sealant (Mitsubishi Genuine Parts
number MD970389 or equivalent) to the oil pump case.
Apply sealant as indicated by the broken line in the illustration; the grooves
must be traced and the bolt holes must be surrounded with a bead of sealant.
3. Install the oil pump case assembly to the front of the cylinder block.
NOTE: Be sure to install the oil pump case quickly while the
sealant is wet (within 15 minutes).

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Fig. 103: Tightening Engine Oil Pressure Switch

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
>>F<< OIL PAN, UPPER INSTALLATION 1. Clean both gasket surfaces of the upper oil pan and cylinder block.
2. Apply a 4 mm (0.2 inch) diameter bead of sealant. (Mitsubishi Genuine Parts
number MD970389 or equivalent) to the upper oil pan.
Apply sealant as indicated by the broken line in the illustration; the grooves
must be traced and the bolt holes must be surrounded with a bead of sealant.
CAUTION: When installing the upper oil pan, be sure not to
expel the sealant from the oil pan flange at

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor