MITSUBISHI ENDEAVOR 2004 Service Repair Manual

Using a suitable pulling tool, pull the overrunning clutch stop ring over the snap
ring. See Fig. 14
.
Fig. 14: Installing Stop Ring & Snap Ring

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STARTER SPECIFICATIONS STARTER SPECIFICATIONS Application
In. (mm)
Commutator RunoutStandard
.002" (0.5 mm)
Limit
.004" (.1 mm)
Commutator DiameterStandard
1.16" (29.4 mm)

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

TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS WIRING DIAGRAMS For starting system wiring diagram see STARTING/CHARGING in appropriate
SYSTEM WIRING DIAGRAMS article in ELECTRICAL.
Limit
1.13" (28.8 mm)
Commutator Undercut (Mica) DepthStandard
.20" (.5 mm)
Limit
0.08" (.2 mm)
Brush Length
.28" (7.0 mm)
Pinion Gap
0.2-0.7" (.5-2.0 mm)
Application
Ft. Lbs. (N.m)
Starter Mounting Bolt
21-25 (27-33)
Starter Connector Bolt
21-25 (27-33)
INCH Lbs. (N.m)
Starter Cover Bolt
35-53 (4-6)
Starter Cover Nut
35-53 (4-6)
Starter Cable Nut
80-124 (9-14)

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

2004 BODY & ACCESSORIES
Sunroof Assembly - Endeavor
GENERAL DESCRIPTION A motor-driven inner slide-type glass sunroof with a tilt-up mechanism is adopted
in some models as a standard or optional equipment. Even when the sunroof is fully
closed, a sufficient amount of lighting and a feeling of openness can still be
obtained by opening the sunroof sunshade. SUNROOF ASSEMBLY The sunroof system is controlled by the Simplified Wiring System (SWS). Refer to
SYMPTOM CHART
.
SPECIAL TOOL Fig. 1: Special Tool Chart

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ON-VEHICLE SERVICE WATER TEST Check if there are an
y leaks in the sunroof b
y the followin
g procedure.

2004 Mitsubishi Endeavor LS
2004 BODY & ACCESSORIES Sunroof Assembly - Endeavor


2004 Mitsubishi Endeavor LS
2004 BODY & ACCESSORIES Sunroof Assembly - Endeavor

1. Fully close the roof lid glass.
2. Adjust the water pressure so that water comes out of the hose to a height of
approximately 50 cm (19.7 inches) when the hose is held vertically facing
upwards.
3. Hold the end of the hose approximately 30 cm (11.8 inches) above the roof and
let the water run onto the weatherstrip for 5 minutes or more.
Fig. 2: Performing Water Test

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
4. Check if any water leaks can be found in the room while watering. Even
though there are any water leaks around the roof lid glass, it can be acceptable
as long as water is caught in the drip area.
SUNROOF TIMER FUNCTION CHECK Keep the door closed, turn OFF the ignition switch and check to see if the sunroof
2004 Mitsubishi Endeavor LS
2004 BODY & ACCESSORIES Sunroof Assembly - Endeavor

can be operated for 30 seconds after that. If not, perform troubleshooting (Refer to
SYMPTOM CHART
).
SUNROOF FIT ADJUSTMENT 1. Fully close the roof lid glass.
2. Fully open the sunshade.
3. Loosen the roof lid glass assembly mounting screws. Align the roof lid glass
by moving it backward, forward, up or down along the guide oblong hole so
that the clearance between the
glass and the vehicle bod
y is even.

2004 Mitsubishi Endeavor LS
2004 BODY & ACCESSORIES Sunroof Assembly - Endeavor

Fig. 3: Locating Roof Lid Mounting Screws

Courtes
y of MITSUBISHI MOTOR SALES OF AMERICA
.

2004 Mitsubishi Endeavor LS
2004 BODY & ACCESSORIES Sunroof Assembly - Endeavor

4. Check to be sure that the roof lid glass is flush with the roof panel at corner
areas.
5. Check to be sure that the sunroof operates smoothly. SUNROOF SAFETY FUNCTION CHECK 1. Close the roof lid glass by applying an approximately 10mm (0.39 inch)
thickness solid object placed at a right angle to the roof lid glass.
2. Check to see if the roof lid glass opens after the motor turns when the roof lid
glass catches the object (Refer to SYMPTOM CHART
).
SUNROOF CHECK Check to see that the sunroof operates by pressing the sunroof switch. Perform
troubleshooting if operations malfunction (Refer to SYMPTOM CHART
).
ROOF LID GLASS OPERATION CURRENT CHECK 1. Remove the fuse of the sunroof, then connect the circuit tester as shown.
2004 Mitsubishi Endeavor LS
2004 BODY & ACCESSORIES Sunroof Assembly - Endeavor

Fig. 4: Checking Roof Lid Glass Operation Current

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Turn ON the sunroof switch, then measure the operating current when the roof
lid glass has been halfly slidden.
Standard value: 7 A or less [at 20 ° C (68 ° F)]
3. Check the following areas if the operating current of exceeds the standard
value:
Sunroof installation, deformation and appearance of any foreign
substances. Drive cable installation. Tilting of roof lid glass.
SUNROOF INITIALIZATION
2004 Mitsubishi Endeavor LS
2004 BODY & ACCESSORIES Sunroof Assembly - Endeavor

The sunroof should be initialized when any of the following components are
replaced, the sunroof position is miss timed, the sunroof is in learn mode.
Roof lid glass assembly Sunroof motor Sunroof-ECU
1. Ensure the components are correctly assembled. Ensure all the connectors are
connected securely.
2. If the sunroof is already in learn mode, go to step 3. If the sunroof is not in
learn mode, enter learn mode by i or ii.
i. Disconnect the sunroof-ECU connector while the sunroof is operating.
ii. Activate the jam preventing mechanism five times continuously.
3. Press the sunroof Close switch repeatedly until the sunroof is tilted up fully.
4. Press and hold the sunroof Close switch for at least three seconds.
5. Press the sunroof Close switch until the sunroof closes fully.
6. Press the sunroof Open switch until the sunroof opens fully. Then press the
sunroof Close switch until the sunroof closes fully. The sunroof should work
normally.
OPERATION CHECK Check that the following items. If faulty, replace the sunroof-ECU.
1.Installation condition of the sunroof assembly
2.Installation condition, deformation and contamination of the sunroof drive
cable NOTE: Do not stop the sunroof before it reaches the fully open or
fully closed position during operations in steps 5 and 6
above. If the sunroof has stopped accidentally, repeat the
procedure from step 1 .
CAUTION: Check that the following items are normal before
carrying out this operation check.
2004 Mitsubishi Endeavor LS
2004 BODY & ACCESSORIES Sunroof Assembly - Endeavor

3.Installation of sunroof lid glass
4.Sunroof switch and sunroof motor
Fig. 5: Locating Sunroof Switch

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
BASIC OPERATION BASIC OPERATION NO.
SUNROOF
FUNCTION
REQUIREMENTS FOR
THE SUNROOF TO
FUNCTION
NORMAL
OPERATION
01
OPEN
1. Ignition switch: ON
2. Sunroof switch: OPEN
The sunroof opens fully
and automatically and
stops several centimeter
forward from fully open
position (comfort
position for better wind
noise performance).
Then, when the sunroo
f
switch is operated again,
the sunroof opens
further to full
y open

2004 Mitsubishi Endeavor LS
2004 BODY & ACCESSORIES Sunroof Assembly - Endeavor