MITSUBISHI ENDEAVOR 2004 Service Repair Manual

weather, vehicle speed, in gear or neutral, engine temperature or any other special
conditions. Noises that develop during A/C operation can often be misleading. For example:
what sounds like a failed front bearing or connecting rod, may be caused by loose
bolts, nuts, mounting brackets, or a loose clutch assembly. Verify accessory drive
belt tension (power steering or generator).
Improper accessory drive belt tension can cause a misleading noise when the
compressor is engaged and little or no noise when the compressor is disengaged.
Drive belts are speed-sensitive. That is, at different engine speeds, and depending
upon belt tension, belts can develop unusual noises that are often mistaken for
mechanical problems within the compressor. HANDLING TUBING AND FITTINGS Kinks in the refrigerant tubing or sharp bends in the refrigerant hose lines will
greatly reduce the capacity of the entire system. High pressures are produced in the
system when it is operating. Extreme care must be exercised to make sure that all
connections are pressure tight. Dirt and moisture can enter the system when it is
opened for repair or replacement of lines or components. The following precautions
must be observed. The system must be completely discharged before opening any
fitting of connection in the refrigeration system. Open fittings with caution even
after the system has been discharged. If any pressure is noticed as a fitting is
loosened, allow trapped pressure to bleed off very slowly. Never attempt to rebend formed lines to fit. Use the correct line for the installation
you are servicing. A good rule for the flexible hose lines is keep the radius of all
bends at least 10 times the diameter of the hose.
Sharper bends will reduce the flow of refrigerant. The flexible hose lines should be
routed so that they are at least 80 mm (3.1 inches) from the exhaust manifold. It is
good practice to inspect all flexible hose lines at least once a year to make sure they
are in good condition and properly routed.
On standard
plumbin
g fittin
gs with O-rin
gs, these O-rin
gs are not reusable.

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

ADJUSTMENT 1. Select a quiet area for testing. Duplicate conditions as much as possible.
Switch the compressor on and off several times to clearly identify compressor
noise. To duplicate high ambient conditions (high head pressure), restrict air
flow through the condenser. Install a manifold gauge set to make sure
discharge pressure doesn't exceed 2,070 kPa (300.2 psi).
2. Tighten all compressor mounting bolts, clutch mounting bolt, and compressor
drive belt. Check to assure clutch coil is tight (no rotation or wobble).
3. Check refrigerant hoses for rubbing or interference that can cause unusual
noises.
4. Check refrigerant charge. (Refer to
CHARGING
and
DISCHARGING
).
5. Recheck compressor noise as in Step 1 .
6. If noise still exists, loosen compressor mounting bolts and retighten. Repeat
Step 1 .
7. If noise continues, replace compressor and repeat from Step 1 .
POWER RELAY CHECK FRONT BLOWER RELAY CONTINUITY CHECK
2004 Mitsubishi Endeavor LS
2004 HVAC Heater Air Conditioning, Ventilation - Endeavor

Fig. 277: Identifying Front Blower Relay

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

FRONT BLOWER RELAY CONTINUITY CHART


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

A/C COMPRESSOR CLUTCH RELAY CONTINUITY CHECK BATTERY VOLTAGE
TESTER
CONNECTION
SPECIFIED
CONDITION
Not applied
4 - 5
Open circuit
Connect terminal 1 to the
positive battery terminal

Connect terminal 3 to the
negative battery terminal
4 - 5
Less than 2 ohms

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

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

Fig. 278: Identifying A/C Compressor Clutch Relay

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

A/C COMPRESSOR CLUTCH RELAY CONTINUITY CHART

FAN CONTROL RELAY CONTINUITY CHECK BATTERY VOLTAGE
TESTER
CONNECTION
SPECIFIED
CONDITION
Not applied
1 - 4
Open circuit
Connect terminal 2 to the
positive battery terminal

Connect terminal 3 to the
negative battery terminal
1 - 4
Less than 2 ohms

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

Fig. 279: Identifying Fan Control Relay

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2004 Mitsubishi Endeavor LS
2004 HVAC Heater Air Conditioning, Ventilation - Endeavor

FAN CONTROL RELAY CONTINUITY CHART

IDLE-UP OPERATION CHECK 1. Before inspection and adjustment, set vehicle in the following condition:
Engine coolant temperature: 80 - 90 °C (176.0 - 194.0 °F) Lights, electric cooling fan and accessories: OFF Transmission: Neutral ("N" or "P" position) Steering wheel: Straightforward
2. Check whether or not the idle speed is the standard value.
Refer to
CURB IDLE SPEED CHECK
.
Standard value: 680 +/- 50 r/min

3. Turn on the air conditioning switch and the blower speed selection dial. Engine
idling speed should be within the standard value:
Standard value

At low pressure: 680 +/- 50 r/min

At middle pressure: 730 +/- 50 r/min

At high pressure: 750 +/- 50 r/min

BATTERY VOLTAGE
TESTER
CONNECTION
SPECIFIED
CONDITION
Not applied
2 - 4
Open circuit
Connect terminal 1 to the
positive battery terminal

Connect terminal 3 to the
negative battery terminal
2 - 4
Less than 2 ohms
NOTE: The powertrain control module determines whether the
A/C load is low or high according to the output signal

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

HEATER CONTROL ASSEMBLY AND A/C SWITCH REMOVAL AND INSTALLATION Fig. 280: Removing And Installing Heater Control Assembly

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

HEATER UNIT, HEATER CORE, BLOWER ASSEMBLY AND EVAPORATOR
UNIT
from the A/C-ECU.
NOTE: It is not necessary to make an adjustment, because the
idling speed is automatically adjusted by the ISC
system. If, however, a deviation from the standard value
occurs for some reason, check the ISC system. (Refer
to CURB IDLE SPEED CHECK
).

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

REMOVAL AND INSTALLATIONPre-removal and Post-installation Operation

Refrigerant draining and Refilling (Refer to
CHARGING
and
DISCHARGING
.)
Engine coolant Draining and Refilling (Refer to
13. ENGINE COOLANT
(CHANGE)
.)
Instrument Panel Removal and Installation (Refer to
REMOVAL AND
INSTALLATION
.)
Steering Column Shaft Assembly Removal and Installation (Refer to REMOVAL AND INSTALLATION
.)

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