check engine MITSUBISHI ENDEAVOR 2004 Service Repair Manual

Fig. 2: Anti Lock Brake Component Legend

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
SYSTEM CHECK SOUND When starting the engine, a thudding sound can sometimes be heard coming from
the engine compartment. This is a normal sound during the ABS self-check. ABS OPERATION SOUNDS AND SENSATIONS During normal operation, the ABS makes several sounds that may seem unusual at
first:
A whining sound is caused by the ABS hydraulic unit motor. When pressure is applied to the brake pedal, the pulsation of the pedal causes a
scraping sound. When the brakes are applied firmly, the ABS operates, rapidly applying and
releasing the brakes many times per second. This repeated application and
release of braking forces can cause the suspension to make a thumping sound
and the tires to s
queak.

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

LONG STOPPING DISTANCES ON LOOSE ROAD SURFACESWhen braking on loose surfaces like snow-covered or gravel roads, the stopping
distance can be longer for an ABS-equipped vehicle than the stopping distance for a
vehicle with a conventional brake system. SHOCK AT STARTING CHECK Shock may be felt when the brake pedal is lightly pressed while driving at a low
speed. This is a normal characteristic because the ABS system operation check is
carried out when vehicle speed is 8 km/h (5 mph) or less. ANTI-LOCK BRAKING SYSTEM (ABS) DIAGNOSIS INTRODUCTION TO ANTI-LOCK BRAKING SYSTEM DIAGNOSIS The anti-lock braking system (ABS) operates differently from conventional brake
systems. These differences include sounds, sensations, and vehicle performance that
owners and service technicians who are not familiar with ABS may not be used to.
Some operational characteristics may seem to be malfunctions, but they are simply
signs of normal ABS operation. When diagnosing the ABS system, keep these
operational characteristics in mind. Inform the owner of the kind of performance
characteristics to expect from an ABS-equipped vehicle. ABS DIAGNOSTIC TROUBLE CODE DETECTION CONDITIONS ABS diagnostic trouble codes (ABS DTCs) are set under different conditions,
depending on the malfunction detected. Most ABS DTCs will only be set during
vehicle operation. Some ABS DTCs will also be set during the ABS self-check
immediately after the engine is started.
When you check if an ABS DTC will be displayed again after the DTC has been
erased, you should duplicate the ABS DTC set conditions. Depending on the
detection timing and set conditions for the specific ABS DTC, you must either drive
the vehicle or turn the engine off and restart it. To set the proper conditions for that
DTC again, refer to ABS DTC SET CONDITIONS
for each ABS DTC that you
are trying to reset.
ABS DIAGNOSTIC TROUBLESHOOTING STRATEGY
2004 Mitsubishi Endeavor LS
2004 BRAKES Anti-Lock Braking System (ABS) - Endeavor

Connector

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Start the engine.
3. Set scan tool MB991958 to the data reading mode, and check the data list
items by driving the vehicle.
Item 01 (DTC C1200 is set): Front right ABS sensor Item 02 (DTC C1205 is set): Front left ABS sensor Item 03 (DTC C1210 is set): Rear right ABS sensor Item 04 (DTC C1215 is set): Rear left ABS sensor
4. Turn the ignition switch to the "LOCK" (OFF) position.
Q: Does the speedometer indication match the scan tool indication?
YES: It can be assumed that this malfunction is intermittent. Refer to
HOW TO COPE WITH INTERMITTENT MALFUNCTIONS
.
NO: Go to Step 4.
STEP 4. Measure the voltage at ABS-ECU connector A-02.
1. Disconnect the connector A-02, and connect special tool ABS Check
Harness (MB991970) to the wiring harness-side connector.
2. Turn the ignition switch to the "ON" position.
3. Measure the voltage between the relevant signal and ground terminals in
the ABS sensor circuit and body ground. It should be less than 1V.
DTC C1200 is set: Between signal terminal 9 and body ground, and
between ground terminal 10 and body ground DTC C1205 is set: Between signal terminal 26 and body ground, and
between ground terminal 16 and body ground DTC C1210 is set: Between signal terminal 11 and body ground, and between
ground terminal 17 and bod
y ground NOTE: Do not connect special tool ABS Check Harness
(MB991970) to the ABS-ECU.

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

4. After checking that the selector lever is in "P" range, start the engine.
5. Select "Interactive Diagnosis" from the start-up screen.
6. Select "System Select."
7. Choose "ABS" from the "CHASSIS" tab.
8. Select "Actuator Test" from "ABS" screen
Fig. 152: Identifying Scan Tool Actuator Test

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
9. Choose an appropriate item for hydraulic unit check.
10. Turn the wheel by hand and check the change in braking force when the brake
pedal is depressed. When using the braking force tester, depress the brake
pedal until the braking force is at the following values, and check that the
brakin
g force chan
ges to the brake dra
g force readin
g taken in ste
p 2 when the
NOTE: The ABS system will switch to the scan tool mode and
the ABS warning light will illuminate.
NOTE: When the ABS has been interrupted by the fail-safe
function, scan tool MB991958 actuator testing cannot
be used.

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

If the engine is started using a booster cable when the battery is completely flat, and
the vehicle is then driven without waiting for the battery to be recharged, the engine
may misfire and it may not be possible to drive the vehicle. This is because the ABS
consumes a large amount of current when carrying out its initial checks. If this
happens, recharge the battery fully. HYDRAULIC UNIT REMOVAL AND INSTALLATION
with the ABS-ECU connector disconnected or with
the ABS not operating for any other reason.
NOTE:
The ABS-ECU is integrated in the hydraulic unit. For vehicles with ASC, refer to HYDRAULIC UNIT
.

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

SYMPTOM CHART Fig. 3: Symptom Chart

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
SYMPTOM PROCEDURES INSPECTION PROCEDURE 1: VEHICLE PULLS TO ONE SIDE WHEN BRAKES ARE APPLIED DIAGNOSIS
STEP 1. Check for oil, water, etc., on the pad contact surface of all brakes.
Q: Is oil, water, etc., on the pad contact surface?
YES: Replace the part and determine the source/cause of foreign material.
Then go to Step 5 .
NO: Go to Step 2.
STEP 2. Check disc brake pistons for smooth operation.
1. With engine not running, depress the brake pedal rapidly several times to
deplete booster vacuum reserves.
2. Test each disc brake assembly one at a time.
a. Remove the lower caliper bolt, then remove caliper from mount.
b. Have an assistant slowly depress the brake pedal. Confirm piston(s)
extend slowl
y and smoothl
y with no
jum
piness. Re
peat for each disc

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

and no contamination is found
.
Q: Is there a fault?
YES: Refill or replace with the specified brake fluid DOT 3 or DOT 4.
Bleed the brakes if necessary (Refer to PROPORTIONING VALVE
FUNCTION TEST < Vehicles without ABS>
). Then go to Step 7 .
NO: Go to Step 2.
STEP 2. Check for spongy (not firm brakes).
1. With engine not running, depress the brake pedal rapidly several times to
deplete booster vacuum reserve.
2. With the brake pedal fully released, depress the brake pedal slowly until it
stops.
3. With a measuring device (ruler, etc.) next to the brake pedal, depress the
pedal firmly and measure the distance the pedal traveled.
Q: Is the distance greater than 20 mm (0.8 inch)?
YES: Bleed the brakes to remove air in the fluid (Refer to
PROPORTIONING VALVE FUNCTION TEST < Vehicles without
ABS>
). Then go to Step 7 .
NO: Go to Step 3.
STEP 3. Check the brake booster function.
Refer to BRAKE PEDAL FREE PLAY
.
Q: Is there a fault?
YES: Replace the brake booster. Then go to Step 7 .
NO: Go to Step 4.
STEP 4. Check for pinched or restricted brake tube or hose.
Q: Is there a pinched or restricted brake tube or hose?
YES: Replace that complete section of brake tube or brake hose. Then go

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

to Step 7 .
NO: Go to Step 5.
STEP 5. Check for oil, water, etc., on the pad contact surfaces of all
brakes.
Q: Is oil, water, etc., on the pad contact surface?
YES: Replace the part and determine the source/cause of foreign material.
Recheck symptom. Then go to Step 7 .
NO: The procedure is complete. If condition persists for vehicles without
ABS, go to Step 6.
STEP 6. Check the proportioning valve operation. < Vehicles without
ABS>
Refer to PROPORTIONING VALVE FUNCTION TEST < Vehicles
without ABS>
.
Q: Is there a fault?
YES: Replace the proportioning valve. Then go to Step 7.
NO: Go to Step 7.
STEP 7. Recheck symptom.
Q: Is the symptom eliminated?
YES: The procedure is complete.
NO: Start over at Step 1 . If a new symptom surfaces, refer to the
appropriate SYMPTOM CHART
.
INSPECTION PROCEDURE 3: INCREASED PEDAL STROKE (REDUCED PEDAL-TO-FLOOR BOARD
CLEARANCE) DIAGNOSIS
STEP 1. Check for spongy (not firm) brakes.
1. With engine not running, depress the brake pedal rapidly several times to
de
plete booster vacuum reserve.

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

2. If the brake pedal play is not within the standard value, check the following,
and adjust or replace if necessary:
Excessive play between the brake pedal and the clevis pin, or between the
clevis pin and the brake booster operating rod Brake pedal height Installation position of the stop light switch, etc.
CLEARANCE BETWEEN BRAKE PEDAL AND DASH PANEL 1. Turn up the carpet, etc. under the brake pedal.
2. Start the engine, depress the brake pedal with approximately 500 N (112
pounds) of force, and measure the clearance between the brake pedal and the
dash panel.
Standard value: 110 mm (4.33 inches) or more [From the surface of dash
panel to the face of
pedal
pad]

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

3. If the clearance is outside the standard value, check for air trapped in the brake
line and thickness of the disc brake pad. And then adjust and replace defective
parts as required.
4. Return the carpet etc. to its original position. BRAKE BOOSTER OPERATING TEST 1. For simple checking of the brake booster operation, carry out the following
tests:
1. Run the engine for one or two minutes, and then stop it. If the pedal
depresses fully the first time but gradually becomes higher when
depressed succeeding times, the booster is operating properly. If the pedal
height remains unchanged, the booster is defective. Go to step 2.
Fig. 19: Checking Brake Booster Operation

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor