MITSUBISHI ENDEAVOR 2004 Service Repair Manual

2. With the ignition switch turned to the "ON" position, read the voltage between
terminals number 2 and number 3.
Standard Value: 2.4 - 2.6 V
3. With special tool MB991348 connected, rotate so that the arrow points straight
down. Read output voltage between terminals number 2 and number 3.
Standard Value: 3.4 - 3.6 V
4. If the voltage deviates from the standard value, check the power supply wire
and ground wire. If no problems are found, replace the G-sensor. SPECIFICATIONS FASTENER TIGHTENING SPECIFICATION FASTENER TIGHTENING SPECIFICATION GENERAL SPECIFICATIONS Fig. 166: General Specifications

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
SERVICE SPECIFICATION ITEM
SPECIFICATION
Brake tube flare nut
15 +/- 2 N.m (12 +/- 1 ft-lb)

2004 Mitsubishi Endeavor LS
2004 BRAKES Anti-Lock Braking System (ABS) - Endeavor

Fig. 167: Service Specificatio
n
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2004 Mitsubishi Endeavor LS
2004 BRAKES Anti-Lock Braking System (ABS) - Endeavor

2004 ACCESSORIES/SAFETY EQUIPMENT
Mitsubishi - Air Bag Restraint Systems
DESCRIPTION & OPERATION Supplemental Restraint System (SRS) components on vehicles with single-stage air
bag systems include single-stage driver-side and passenger-side air bag modules,
side impact air bag modules, seat belt pretensioners, front impact sensors, side
impact sensors, SRS Electronic Control Unit (SRS ECU) and an AIR BAG warning
light or SRS warning light.
SRS components on vehicles with dual-stage air bag systems include dual-stage
driver-side and passenger-side air bag modules, side impact air bag modules, seat
belt pretensioners, front impact sensors, side impact sensors, SRS Electronic
Control Unit (SRS ECU), occupant classification sensor, occupant classification
sensor ECU, seat belt switches, AIR BAG warning light or SRS warning light,
PASSENGER AIR BAG OFF warning light and a PASSENGER SEAT BELT
warning light. COMPONENT LOCATIONS Refer to illustration for SRS com
ponent locations. See
Fig. 1
&
Fig. 2
.
WARNING:Accidental air bag deployment is possible. Personal
injury may result. Read and follow all WARNINGS
and AIR BAG SAFETY PRECAUTIONS
before
working on air bag system or related components.

2004 Mitsubishi Endeavor Limited
2004 ACCESSORIES/SAFETY EQUIPMENT Mitsubishi - Air Bag Restraint Systems


2004 Mitsubishi Endeavor Limited
2004 ACCESSORIES/SAFETY EQUIPMENT Mitsubishi - Air Bag Restraint Systems

Fig. 1: Locating Restraint System Components (Single
-stage Air Bag System)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2004 Mitsubishi Endeavor Limited
2004 ACCESSORIES/SAFETY EQUIPMENT Mitsubishi - Air Bag Restraint Systems

Fig. 2: Locating Restraint System Components (Dual
-stage Air Bag System)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

SYSTEM OPERATION CHECK Turn ignition on. AIR BAG warning light should come on for about 7 seconds and
then turn off, indicating SRS is functioning properly. If AIR BAG warning light
does not function as described, SRS is malfunctioning and needs repair. See DIAGNOSTICS
.
AIR BAG SAFETY PRECAUTION
S
WARNING:Accidental air bag deployment is possible. Personal
injury may result. Read and follow all WARNINGS
and AIR BAG SAFETY PRECAUTIONS
before
working on air bag system or related components.

2004 Mitsubishi Endeavor Limited
2004 ACCESSORIES/SAFETY EQUIPMENT Mitsubishi - Air Bag Restraint Systems

Observe these precautions when servicing the air bag system:
Disable SRS before servicing any SRS component. Failure to do this may
result in accidental air bag deployment and possible personal injury. See DISABLING & ACTIVATING AIR BAG SYSTEM
.
After disabling SRS, wait at least 60 seconds before servicing SRS. After servicing, always turn ignition on from outside of vehicle in case of
accidental air bag module deployment. After servicing, check AIR BAG warning light to verify system operation. See SYSTEM OPERATION CHECK
.
Always wear safety glasses when servicing or handling an SRS component. Hearing protection must be worn when performing deployment procedures. DO NOT expose air bag modules, clockspring or SRS ECU to temperatures
greater than 200°F (93°C ). DO NOT expose seat belt pretensioners to temperatures greater than 194°F
(90°C ). When placing a live air bag module on a bench or other surface, always place
air bag module with trim cover facing up and away from surface. This will
reduce motion of air bag module if accidental deployment occurs. After air bag module deploys, surrounding surfaces may contain deposits of
sodium hydroxide, which irritates skin. Always wear safety glasses, rubber
gloves and a long-sleeved shirt during clean-up. Wash hands using mild soap
and water. Follow correct clean-up and disposal procedures. See
DISPOSAL
PROCEDURES
.
Because of critical system operating requirements, DO NOT service any SRS
components. Repairs are only made by replacing defective components. DO NOT allow any electrical source near inflator on back of air bag module. When carrying a live (undeployed) air bag module, trim cover must be pointed
away from body to minimize injury in case of accidental air bag deployment. If instructed to probe wire harness, do so from harness side of connector. DO NOT probe a wire through insulator. Wire will be damaged and eventually
fail due to corrosion. When
performin
g electrical tests,
prevent accidental shortin
g of terminals.

2004 Mitsubishi Endeavor Limited
2004 ACCESSORIES/SAFETY EQUIPMENT Mitsubishi - Air Bag Restraint Systems

Such shorts can damage fuses or components and may cause a second
Diagnostic Trouble Code (DTC) to set, making diagnosis of original problem
more difficult. Never use an analog volt/ohm meter or test light in place of a Digital Volt/Ohm
Meter (DVOM). Use only a DVOM with a maximum test current of 2 mA
(milliamps) at minimum range of resistance measurement. If SRS is not fully functional for any reason, DO NOT drive vehicle until
system is repaired and fully functional. DO NOT remove bulbs, modules,
sensors, or other components or in any way disable system from operating
normally. If SRS is not functional, park vehicle until repairs are made.
DISABLING & ACTIVATING AIR BAG SYSTEM To disable system, turn ignition off. Disconnect negative battery cable. Shield cable
end with electrical tape. Wait at least 60 seconds before servicing air bag system.
To activate system, reconnect negative battery cable. Check system operation. See SYSTEM OPERATION CHECK
.
DISPOSAL PROCEDURES DEPLOYED AIR BAG OR SEAT BELT PRETENSIONER Place deployed component in a strong plastic bag and seal tightly. Dispose of
component as you would any other part. No other special disposal procedure is
required. UNDEPLOYED AIR BAG OR SEAT BELT PRETENSIONER
WARNING:Accidental air bag deployment is possible. Personal
injury may result. Read and follow all WARNINGS
and AIR BAG SAFETY PRECAUTIONS
before
working on air bag system or related components.
NOTE: Undeployed air bag modules must be deployed before
disposal. Disposing of an undeployed air bag may violate
federal, state and/or local laws. This also applies to vehicles
that are to be scrapped.

2004 Mitsubishi Endeavor Limited
2004 ACCESSORIES/SAFETY EQUIPMENT Mitsubishi - Air Bag Restraint Systems

On-vehicle Deployment 1. Before proceeding, see
AIR BAG SAFETY PRECAUTIONS
. Move vehicle
to an isolated area. Open all doors and windows. Disconnect and shield
negative battery cable end. Disconnect positive battery cable. Remove battery
from vehicle. Wait at least 60 seconds before continuing.
2. To deploy driver-side air bag module, remove steering column lower cover.
Disconnect lower clockspring Yellow 4-pin connector. Cut harness side of
connector from wire harness and strip ends of driver-side air bag module wires
on harness side of clockspring connector. See
WIRING DIAGRAMS
.
3. To deploy passenger-side air bag module, remove glove box and glove box
outer case. Disconnect passenger-side air bag module Red connector.
4. To deploy side impact air bag module, disconnect appropriate side impact air
bag module Red connector, located under front seat.
5. To deploy seat belt pretensioner, disconnect appropriate seat belt pretensioner
connector, located at seat belt pretensioner.
6. Fabricate a de
ployment harness usin
g two wires at least 20 feet
(6.1 m
) in
WARNING:Air bag modules and seat belt pretensioners make
loud noises during deployment. Air bag module and
seat belt pretensioner deployment could cause
personal injury. Always deploy components
outdoors and away from people. Never deploy air
bag modules with trim cover face down.
NOTE: If vehicle is to be scrapped, perform On-vehicle
deployment. See ON
-VEHICLE DEPLOYMENT
. If vehicle
will continue to be operated, perform Off-vehicle
Deployment. See OFF
-VEHICLE DEPLOYMENT
.
NOTE: Driver-side and passenger-side air bag modules will be
either single-stage or dual-stage. Consult wiring
diagrams to ensure correct wires are cut and spliced
prior to deployment. See WIRING DIAGRAMS
.

2004 Mitsubishi Endeavor Limited
2004 ACCESSORIES/SAFETY EQUIPMENT Mitsubishi - Air Bag Restraint Systems

length. Strip insulation from ends of wires. Connect wires at one end of harness
to clockspring connector stripped wires and cover connections with insulating
tape. Temporarily wrap other end of harness wires together to prevent
unexpected air bag deployment.
7. Stretch deployment harness as far away from vehicle as possible. Roll up
vehicle windows to lessen deployment noise and cover vehicle with car cover,
in case glass should shatter during deployment. Ensure area is clear of people.
Untwist deployment harness wire ends. Touch wire ends to 12 volt battery
terminals to deploy driver-side air bag module.
8. Repeat procedure for remaining air bag modules and seat belt pretensioners.
Use SRS Air Bag Adapter Harness (MB686560) for passenger-side and side
impact air bag modules. Use SRS Adapter Harness (MR991885) for seat belt
pretensioners. If any component fails to deploy, stay away from vehicle and
contact manufacturer for further instructions. Allow 30 minutes for air bag
modules to cool.
Off-vehicle Deployment 1. Before proceeding, see
AIR BAG SAFETY PRECAUTIONS
. Turn ignition
switch to LOCK position. Disconnect negative battery cable. Shield cable end.
Wait at least 60 seconds before continuing. Disconnect positive battery cable.
Remove battery from vehicle.
2. Fabricate a deployment harness using two wires at least 20 feet (6.1 m) in
length. Strip insulation from ends of wires. Twist together one end of wires
temporarily. Remove driver-side air bag module. See
DRIVER
-SIDE AIR
BAG MODULE & CLOCKSPRING
under REMOVAL &
INSTALLATION. Place driver-side air bag module on surface face up. Touch
vehicle body with bare hands to discharge static electricity from body. Cut
driver-side air bag module connector from pigtail leads. Strip insulation from
ends of
pigtail wires. Attach remainin
g ends of de
ployment harness to
pigtail NOTE: Driver-side and passenger-side air bag modules will be
either single-stage or dual-stage. Consult wiring
diagrams to ensure correct wires are cut and spliced
prior to deployment. See WIRING DIAGRAMS
.

2004 Mitsubishi Endeavor Limited
2004 ACCESSORIES/SAFETY EQUIPMENT Mitsubishi - Air Bag Restraint Systems

leads. Wrap connections with electrical tape.
3. Secure driver-side air bag module to an old tire and wheel. Run harness wires
through hole at rear of air bag module, through hole in wheel and out beneath
tire. Stack 3 more tires on top of first tire. Tie tires together with rope in four
locations. Untwist ends of deployment harness. Connect ends of deployment
harness to terminals of a 12-volt battery to deploy air bag module. If air bag
module fails to deploy, go to step 7 . If air bag module deploys, wait at least 30
minutes for air bag module to cool before touching. Go to next step.
4. Remove remaining components. See
REMOVAL & INSTALLATION
. For
passenger-side air bag modules and seat belt pretensioners, place component
on ground at least 20 feet (6.1 m) away from people or objects. Ensure trim
cover of passenger-side air bag module is facing up. For side impact air bag
modules, position seat back so rear of seat back is in contact with ground
surface, at least 20 feet (6.1 m) away from people or objects.
5. Make a deployment harness using two wires at least 20 feet (6.1 m) in length.
Temporarily twist wires on one end of harness together to prevent unexpected
deployment. Connect wires at other end of harness to stripped wires of SRS
Air Bag Adapter Harness "B" (MB686560) for passenger-side or side impact
air bag modules or SRS Air Bag Adapter Harness (MR991885) for seat belt
pretensioners.
6. Wrap connections with insulating tape. Connect appropriate adapter harness to
component connector. If deploying passenger-side air bag module or seat belt
pretensioner, secure component to a scrap tire and wheel. Run harness wires
through air bag module mounting hole, through hole in wheel and out beneath
tire. Stack 3 more tires on top of first tire. Tie tires together with rope in four
locations.
7. To deploy appropriate component, connect ends of deployment harness to
terminals of a 12-volt battery. If any component fails to deploy, stay away from
component. Contact manufacturer for further instructions. After deployment,
allow at least 30 minutes for component to cool before touching. Tightly seal
deployed component in a strong plastic bag and dispose of it as you would any
other part.
POST
-COLLISION INSPECTION

2004 Mitsubishi Endeavor Limited
2004 ACCESSORIES/SAFETY EQUIPMENT Mitsubishi - Air Bag Restraint Systems