MITSUBISHI ENDEAVOR 2004 Service Repair Manual

1. Align the mating marks of the clock spring.
Fig. 253: Aligning Mating Marks Of Clock Spring

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
1. Turn the clock spring clockwise fully. Then turn it back approximately 3-
3/4 turns counterclockwise to align the mating marks.
2. Turn the front wheels to the straigh
t-ahead position. Then install the clock WARNING:Ensure that the clock spring's mating marks are
properly aligned. If not, the steering wheel may not
rotate completely during a turn, or the flat cable in
the clock spring could be damaged, This would
prevent normal SRS operation and possibly cause
serious injury to the driver.

2004 Mitsubishi Endeavor LS
2004 BRAKES Traction Control, Active Skid Control System - Endeavor

spring to the column switch.
2. Align the mating marks of the steering wheel sensor as follows.
Fig. 254: Connecting Steering Wheel Sensor Connector

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
1. Turn the steering wheel sensor clockwise fully. Then turn it back
approximately 2-3/4 turns counterclockwise to align the mating marks.
2. Ali
gn the matin
g marks on the clock s
prin
g and the steerin
g wheel sensor, CAUTION: Ensure that the steering wheel sensor's mating
marks are properly aligned. If not, the steering
wheel sensor could be damaged.

2004 Mitsubishi Endeavor LS
2004 BRAKES Traction Control, Active Skid Control System - Endeavor

and install the steering wheel sensor to the column switch assembly.
3. Connect the steering wheel sensor connector.
SPECIFICATIONS FASTENER TIGHTENING SPECIFICATION FASTENER TIGHTENING SPECIFICATION SERVICE SPECIFICATIONS SERVICE SPECIFICATION ITEM
SPECIFICATION
Brake tube flare nut
15 +/- 2 N.m (12 +/- 1 ft-lb)
ITEM
STANDARD VALUE
Wheel speed sensor internal resistance kohm
1.24 - 1.64

2004 Mitsubishi Endeavor LS
2004 BRAKES Traction Control, Active Skid Control System - Endeavor

2004 STARTING & CHARGING SYSTEMS
Starters - Endeavor
DESCRIPTION & OPERATION If the ignition switch is turned to START position, current flows in the coil
provided inside magnetic switch, attracting the plunger. When plunger is attracted,
the lever connected to plunger is actuated to engage starter clutch. On the other
hand, attracting plunger will turn on magnetic switch, allowing "B" terminal and
"M" terminal to conduct. Thus, current flows to engage starter motor. When
ignition switch is returned to ON position after starting engine, starter clutch is
disengaged from ring gear.
An overrunning clutch is provided between pinion and armature shaft to prevent
damage to starter.
When the ignition switch is switched to the START position while the selector leve
r
is at the "P" or "N" range, the contact (magnetic switch) of the starter is switched
ON and the starter motor is activated.
ADJUSTMENT PINION GAP 1. Disconnect the field coil wire from the "M" terminal of magnetic switch.
2. Connect a 12V battery between "S" terminal and "M" terminal. See Fig. 1
.
3. Set switch to ON and pinion will move out.
4. Check the pinion to stopper clearance (pinion gap) with a feeler gauge. See
Fig. 2
.
5. If the pinion gap is out of specification, adjust by adding or removing gasket(s)
between the ma
gnetic switch and front bracket. CAUTION: To prevent coil from burning, DO NOT apply voltage
to starter assembly for more than 10 seconds.

2004 Mitsubishi Endeavor Limited
2004 STARTING & CHARGING SYSTEMS Starters - Endeavor


2004 Mitsubishi Endeavor Limited
2004 STARTING & CHARGING SYSTEMS Starters - Endeavor

Fig. 1: Adjusting Pinion Gap

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

2004 Mitsubishi Endeavor Limited
2004 STARTING & CHARGING SYSTEMS Starters - Endeavor

Fig. 2: Measuring Pinion Gap

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA
TROUBLE SHOOTING STARTER MOTOR DOES NOT OPERATE
Check the starter (coil). Check for poor contact at the battery terminals and starter. Check the transmission ran
ge switch.
WARNING:Battery posts, terminals and related accessories
contain lead and lead compounds. Wash hands after
handling.

2004 Mitsubishi Endeavor Limited
2004 STARTING & CHARGING SYSTEMS Starters - Endeavor

STARTER MOTOR DOES NOT STOPCheck the magnetic switch. ON-VEHICLE TESTING STARTER MOTOR DOES NOT OPERATE 1. Is the battery in good condition? If Yes, go to the next step. If No, then charge
or replace battery.
2. Disconnect the starter motor "S" (solenoid) terminal connector. Using a jumper
wire, apply battery positive voltage to starter motor "S" (solenoid) terminal.
Does starter motor operate normally? If Yes, then check ignition switch,
transmission range switch and the line between the battery and starter motor
"S" (solenoid) terminal. If No, then go to the next step.
3. Check if the cable between starter "B" (battery) terminal and battery positive
terminal for connection and continuity. Is the starter cable in good condition? I
f
Yes, then go to the next step. If No, then repair or replace the cable.
4. Check the connection and continuity of the cable between starter motor body
and the negative battery terminal. Is the ground line in good condition? If Yes,
then go to the next step. If No, then repair or replace cable.
5. Is the starter motor in good condition? If Yes, problem is excessive rotational
resistance of the engine. If No, then replace the starter motor.
BENCH TESTING MAGNETIC SWITCH PULL-IN TEST 1. Disconnect field coil wire from "M" terminal of the magnetic switch. See Fig.
3 . WARNING:Battery posts, terminals and related accessories
contain lead and lead compounds. Wash hands after
handling.
CAUTION: To prevent coil from burning, DO NOT apply voltage
to starter assembly for more than 10 seconds.

2004 Mitsubishi Endeavor Limited
2004 STARTING & CHARGING SYSTEMS Starters - Endeavor

2. Connect a 12-volt battery between "S" terminal and "M" terminal.
3. If the pinion moves out, the pull-in coil is good. If it doesn't, replace the
magnetic switch.
Fig. 3: Magnetic Switch Pull
-in Test

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
MAGNETIC SWITCH HOLD IN TEST
CAUTION: To prevent coil from burning, DO NOT apply voltage
to starter assembly for more than 10 seconds.

2004 Mitsubishi Endeavor Limited
2004 STARTING & CHARGING SYSTEMS Starters - Endeavor

1. Disconnect the field coil wire from "M" terminal of the magnetic switch. See
Fig. 4
.
2. Connect 12-volt battery between the "S" terminal and body.
3. Manually pull out the pinion as far as the pinion stopper position.
4. If the pinion remains out, everything is operating properly. If pinion moves in,
hold-in circuit is open. Replace the magnetic switch.
Fig. 4: Magnetic Switch Hold
-in Test

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
MAGNETIC SWITCH RETURN TEST
2004 Mitsubishi Endeavor Limited
2004 STARTING & CHARGING SYSTEMS Starters - Endeavor

1. Disconnect the field coil wire from the "M" terminal of the magnetic switch.
SeeFig. 5
.
2. Connect a 12-volt battery between the "M" terminal and body.
3. Pull the pinion out and release. If the pinion quickly returns to its original
position, everything is operating properly. If it doesn't, replace the magnetic
switch. WARNING:Be careful not to get your fingers caught when
pulling out the pinion.
CAUTION: To prevent coil from burning, DO NOT apply voltage
to starter assembly for more than 10 seconds.

2004 Mitsubishi Endeavor Limited
2004 STARTING & CHARGING SYSTEMS Starters - Endeavor