MITSUBISHI ENDEAVOR 2004 Service Repair Manual

When a vehicle has been involved in a collision, certain components of the passive
restraint system must be inspected or replaced. See
AIR BAG/SRS
COMPONENT INSPECTION & REPLACEMENT TABLES
article in the
GENERAL INFORMATION section.
REMOVAL & INSTALLATION DRIVER-SIDE AIR BAG MODULE & CLOCKSPRING Removal & Installation (With Single-stage AIR Bag System) 1. Before proceeding, see
AIR BAG SAFETY PRECAUTIONS
. Ensure front
wheels are in straight-ahead position. Turn ignition off. Disable air bag system.
See
DISABLING & ACTIVATING AIR BAG SYSTEM
.
2. Remove lower cover from steering wheel. Remove driver-side air bag module
bolts from rear of steering wheel. Remove driver-side air bag module. See
Fig.
3 . Remove damper weight from steering wheel. Remove steering wheel nut
and discard. Using Steering Wheel Puller (MB990803), remove steering wheel.
3. Remove upper and lower steering column covers. Disconnect clockspring
electrical connectors. Remove clockspring screws. Remove clockspring from
steering column.
4. To install, reverse removal procedure. If necessary, center clockspring. See CENTERING CLOCKSPRING
under ADJUSTMENTS. Tighten
clockspring screws, NEW steering wheel nut and driver-side air bag module
bolts to specification. See
TORQUE SPECIFICATIONS
. Activate air bag
s
ystem. 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

Fig. 3: Identifying Driver
-side Air Bag Module & Clockspring (Single
-stage
Air Bag System)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Removal & Installation (With Dual Stage AIR Bag System) 1. Before proceeding, see
AIR BAG SAFETY PRECAUTIONS
. Ensure front
wheels are in straight-ahead position. Turn ignition off. Disable air bag system.
See
DISABLING & ACTIVATING AIR BAG SYSTEM
.
2. Remove lower cover from steering wheel. Remove driver-side air bag module
bolts from rear of steering wheel. Remove driver-side air bag module. See Fig.
4 . Remove damper weight from steering wheel. Remove steering wheel nut
and discard. Using Steering Wheel Puller (MB990803), remove steering wheel.
3. Remove upper and lower steering column covers. Disconnect clockspring
electrical connectors. Remove clocks
prin
g screws. Remove clocks
prin
g from

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

steering column.
4. To install, reverse removal procedure. If necessary, center clockspring. See
CENTERING CLOCKSPRING
under ADJUSTMENTS. Tighten
clockspring screws, NEW steering wheel nut and driver-side air bag module
bolts to specification. See TORQUE SPECIFICATIONS
. Activate air bag
system.
Fig. 4: Identifying Driver
-side Air Bag Module & Clockspring (Dual
-stage Air
Bag System)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
FLOOR CONSOLE ASSEMBLY (WITH DUAL STAGE AIR BAG SYSTEM) Removal & Installation 1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS
. Disable air
bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM
.
2. Remove inner box tray. See Fig. 5
. Remove plate. Remove cup holder,
Remove left and right side covers. Remove gearshift lever panel. Remove
accessory panel. Remove rear A/C switch and accessory socket. Remove floor
console assembl
y.

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

3. To install, reverse removal procedure. Activate air bag system.
Fig. 5: Identifying Floor Console Assembly Components

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
FRONT IMPACT SENSOR Removal & Installation 1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS
. Turn ignition
off. Disable air bag system. See DISABLING & ACTIVATING AIR BAG
SYSTEM
.

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

2. Disconnect appropriate front impact sensor connector. Disconnect electrical
sensor. Remove front impact sensor nuts. Remove front impact sensor. See
Fig. 6
or Fig. 7
.
3. To install, reverse removal procedure. Tighten front impact sensor nuts to
specification. See TORQUE SPECIFICATIONS
. Activate air bag system.
Fig. 6: Identifying Front Impact Sensor (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. 7: Identifying Front Impact Sensor (Dual
-stage Air Bag System)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
INSTRUMENT PANEL Removal & Installation 1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS
. Turn ignition
off. Disable air bag system. See DISABLING & ACTIVATING AIR BAG
SYSTEM
.
2. Remove driver-side air bag module and steering wheel. See DRIVER
-SIDE
AIR BAG MODULE & CLOCKSPRING
. Remove front scuff plates.
Remove cowl side trim. Remove floor console assembl
y. See FLOOR

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

CONSOLE ASSEMBL
Y . Remove left and right A-pillar trim panels.
Remove hood lock release handle.
3. Remove end panel. See Fig. 8
. Remove driver-side knee bolster. Remove fog
light switch. Remove steering column upper and lower covers. Remove
combination meter assembly. Remove center panel assembly. Remove air
vents. Remove radio panel. Remove AC-heater control assembly.
4. Remove hazard warning switch. Remove console meter hood. Remove multi-
center display unit. Remove audio components. Remove glove box assembly.
Remove left and right speaker covers. Remove speakers. Disconnect
clockspring and steering column switch connectors. Remove photo sensor and
photo sensor clamp.
5. Remove interior temperature sensor. Disconnect passenger-side air bag module
connector. Remove left and right center instrument panel brackets. Disconnect
remaining electrical connectors. Remove instrument panel nuts and bolts.
Remove instrument panel.
6. To install, reverse removal procedure. Tighten NEW steering wheel nut and
drive
r-side air ba
g module bolts to s
pecification. Activate air ba
g system.

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

Fig. 8: Identifying Instrument Panel Components

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

Removal & Installation 1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS
. Disable air
bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM
.
Remove passenger-side front seat assembly.
2. To install, reverse removal procedure. Perform occupant classification
calibration procedure. See OCCUPANT CLASSIFICATION SENSOR
under REMOVAL & INSTALLATION. Tighten front seat nuts and bolts to
specification. See TORQUE SPECIFICATIONS
. Activate air bag system.
PASSENGER-SIDE AIR BAG MODULE Removal & Installation (Single Stage AIR Bag System) 1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS
. Turn ignition
off. Disable air bag system. See DISABLING & ACTIVATING AIR BAG
SYSTEM
.
2. Remove instrument panel. See INSTRUMENT PANEL
. Remove passenger-
side air bag module bracket. See Fig. 9
. Remove passenger-side air bag
module.
3. To install, reverse removal
procedure. Activate ai
r ba
g system.

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

Fig. 9: Identifying Passenger
-side Air Bag Module (Single
-stage Air Bag
System)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Removal & Installation (Dual Stage AIR Bag System) 1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS
. Turn ignition
off. Disable air bag system. See DISABLING & ACTIVATING AIR BAG
SYSTEM
.
2. Remove instrument panel. See INSTRUMENT PANEL
. Remove passenger-
side air bag module bracket. See Fig. 10
. Remove passenger-side air bag
module.
3. To install, reverse removal
procedure. Activate ai
r ba
g system.

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