valve cover MITSUBISHI ENDEAVOR 2004 Service Repair Manual

2004 TRANSMISSION
Automatic Transaxle Overhaul - Endeavor
GENERAL INFORMATION This automatic transaxle is made up of the following main parts.
The gear train is made up of 3 multi-plate clutches, 2 multi-plate brakes and 2
planetary gears made up of a sun gear, carrier, pinion gear and annulus gear.
The torque converter employs a 3 element, 1 step, 2 phase lock-up clutch.
The cases consist of a converter housing, transaxle case, rear cover and a valve
body cover.
Parts related to oil pressure regulation are the oil pump, which pressurizes the oil;
the regulator, which controls the pressure setting; the solenoid valves, which
changes the oil pressure with electrical signals; the pressure control valve, which
controls the oil pressure coming from the solenoid valve that effects each clutch and
brake; each kind of valve, which carry out the retention of the oil pressure through
the lines; and finally the valve body, which houses all the valves. SECTIONAL VIEW < F4A5A >
2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor


2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 16: Identifying Sealing Cap

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
10. Remove the valve bod
y cover.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 17: Identifying Valve Body Cover

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
11. Remove the manual control shaft detent.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 139: Installing Manual Control Shaft Detent

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
98. Apply a 2 mm (0.08 inch) diameter bead of sealant (MITSUBISHI Genuine
Part number MD974421 or equivalent) to the valve body cover in the area
shown.
NOTE: Be sure to install the case quickly while the sealant is
wet (with 15 minutes).
NOTE: After installation, keep the sealed area awa
y from the oil
for approximately one hour.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 140: Applying Bead Of Sealant To Valve Body Cover

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
99. Install the valve body cover, and then tighten its mounting bolts to the
specified torque.
Tightening torque: 11 +/- 1 N.m (95 +/- 8 in-lb)

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 141: Installing Valve Body Cover Mounting Bolts

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
100. Install the Sealing cap and tighten the bolt to the specified torque.
Tightening torque: 5.0 +/- 1.0 N.m (43 +/- 8 in-lb)
2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

The master cylinder used has no check valve, so if bleeding is carried out by the
following procedure, bleeding of air from the brake pipeline will become easier.
(When brake fluid is not contained in the master cylinder).
1. Fill the reserve tank with brake fluid.
2. Keep the brake pedal depressed.
3. Have another person cover the master cylinder outlet with a finger.
Fig. 26: Identifying Master Cylinder Outlet

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

Fig. 54: Removing Camshaft Oil Seal

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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

DISCHARGING SYSTEM Use the refrigerant recovery unit to discharge refrigerant gas from the system. REFILLING OF OIL IN THE A/C SYSTEM Too little oil will provide inadequate compressor lubrication and cause a
compressor failure. Too much oil will increase discharge air temperature.
When a compressor is installed at the factory, it contains 140 cm
3 (4.7 fl.oz) of
refrigerant oil. While the A/C system is in operation, the oil is carried through the
entire system by the refrigerant. Some of this oil will be trapped and retained in
various parts of the system.
When the following system components are changed, it is necessary to add oil to
the system to replace the oil being removed with the component.
Compressor oil: SUN PAG 56

Quantity:

Evaporator: 60
cm
3 (2.0 fl.oz)

Condenser:
15 cm
3 (0.5 fl.oz)
Suction hose: 10 cm3 (0.3 fl.oz)

PERFORMANCE TEST The vehicles to be tested should be parked out of direct sunlight.
1. Close the high and low-pressure valve of the gauge manifold.
2. Connect the charging hose (blue) to the low-pressure valve and connect the
UNIT
.
NOTE: Refer to the REFRIGERANT RECOVERY AND RECYCLING
UNIT'S INSTRUCTION MANUAL FOR OPERATION OF THE UNIT
.

2004 Mitsubishi Endeavor LS
2004 HVAC Heater Air Conditioning, Ventilation - Endeavor