check engine light MITSUBISHI ENDEAVOR 2004 Service Repair Manual

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

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

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

For belt tension, see ADJUSTMENTS
.
TROUBLE SHOOTING 1. Is battery in good condition?
If Yes, then go to next step. If No, then charge or replace battery.
2. Is generator drive belt in good condition? If Yes, then go to next step. If No, then adjust belt tension or replace belt.
3. Does the generator malfunction light come on when the ignition switch is
turned on? If Yes, then go to next step. If No:
Check the ignition switch.
Check for burnt-out generator malfunction light.
Check the generator.
Check the generator malfunction light-related circuits.
4. Does the generator malfunction light go out after starting the engine? If Yes, then go to next step. If No, check the generator.
5. Is an oscilloscope available? If Yes, then go to next step. If No, then go to step 7 .
6. Does the oscilloscope show a normal wave pattern? If Yes, then go to next step. If No, then check the generator.
7. Turn the engine on and idle at 2500 RPM. Turn the headlights on with the
High Beams on. Be sure that there is voltage between generator terminal B and
the positive battery terminal of 0.5V or less. Check that the voltage between
the negative batter
y terminal and
generator bod
y is 0.5V or less. Are the

2004 Mitsubishi Endeavor Limited
2004 STARTING & CHARGING SYSTEMS Generators & Regulators - Endeavor

4. Connect a clamp-type DC test ammeter with a range of 0-150A to the
generator B terminal output wire.
5. Connect a digital-type voltmeter between the generator B terminal and the
positive battery terminal. (Connect the positive lead of the voltmeter to the B
terminal, and then connect the negative lead of the voltmeter to the positive
battery cable.)
6. Reconnect the negative battery cable.
7. Connect an engine tachometer or scan tool MB991958.
8. Leave the hood open.
9. Start the engine.
10. With the engine running at 2500 RPM, turn the headlights and other lights on
and off to adjust the generator load so that the value displayed on the ammeter
is slightly above 30A. Read the voltmeter. Voltage reading at or below limit
value means voltage drop between generator and batter is OK. There should be
a maximum voltage of 0.3V.
11. If the value displayed on the voltmeter is above the limit value, there is
probably a malfunction in the generator output wire. Check the wiring between
the
generator B terminal and the
positive batter
y terminal
(includin
g fusible
NOTE: The way of disconnecting the generator output wire and
of connecting the ammeter is possibly not found the
problem that the output current is dropping due to the
insufficient connection between terminal B and the
output wire.
NOTE: When the generator output is high and the value
displayed on the ammeter does not decrease to 30A,
set the value to 40A. Read the value displayed on the
voltmeter at this time. In the case the limit value
becomes maximum 0.4V. Adjust the engine speed by
gradually decreasing it until the value displayed on the
ammeter is 30A. Take a reading of the value displayed
on the voltmeter at this time

2004 Mitsubishi Endeavor Limited
2004 STARTING & CHARGING SYSTEMS Generators & Regulators - Endeavor

11. Immediately after setting the headlights to high beam and turning the heater
blower switch to the highest position, increase the engine speed to 2,500 RPM
and read the maximum current output value displayed on the ammeter. Limit
value: 70 percent of nominal current output.
12. The reading on the ammeter should be above the limit value. If the reading is
below the limit value and the generator output wire is normal, remove the
generator from the engine and check the generator.
13. Run the engine at idle speed after the test.
14. Turn the ignition switch to the LOCK (OFF) position.
15. Disconnect the engine tachometer or scan tool MB991958.
16. Disconnect the negative battery cable.
17. Disconnect the ammeter and voltmeter.
18. Connect the negative battery cable.
19. Run the engine for 10 minutes at an idle. REGULATED VOLTAGE TEST Required special tools:
MB991958: Scan Tool MUT
-III Sub Assembly.
NOTE: The current output value will depend on the electrical
load and the temperature of the generator body.
NOTE: If the electrical load is small while testing, the specified
level of current may not be output even though the
generator is normal. In such cases, increase the
electrical load by leaving the headlights turned on for
some time to discharge the battery or by using the
lighting system in another vehicle, and then test again.
NOTE: The specified level of current also may not be output if
the temperature of the generator body or the ambient
temperature is too high. In such cases, cool the
generator and then test again.

2004 Mitsubishi Endeavor Limited
2004 STARTING & CHARGING SYSTEMS Generators & Regulators - Endeavor

Generator installation. Check to be sure that the battery installed in the vehicle is fully charged. Generator drive belt tension. Fusible link. Abnormal noise from the generator while the engine is running.
2. Turn the ignition switch to the LOCK (OFF) position.
3. Disconnect the negative battery cable.
4. Use the special tool (Generator Harness Connector: MB991519) to connect a
digital-type voltmeter between the generator S terminal and ground. (Connect
the positive lead of the voltmeter to the S terminal, and then connect the
negative lead of the voltmeter to a secure ground or to the negative battery
terminal.)
5. Connect a clamp-type DC test ammeter with a range of 0-150A to the
generator B terminal output wire.
6. Reconnect the negative battery cable.
7. Connect an engine tachometer, or scan tool MB991958.
8. Turn the ignition switch to the ON position and check that the reading on the
voltmeter is equal to the battery positive voltage.
9. Check to be sure that all lights and accessories are off.
10. Start the engine.
11. Increase the engine speed to 2,500 RPM
12. Read the value displayed on the voltmeter when the current output by the
generator becomes 10A or less.
13. If the voltage reading conforms to the value in the voltage regulation table,
then the voltage regulator is operating normally. If the voltage is outside the
standard value, there is a malfunction of the volta
ge re
gulator or the
generator.
NOTE: If the voltage is 0V, the cause is probably an open
circuit in the wire or fusible link between the generator
S terminal and the battery positive terminal or
malfunctioning voltmeter.

2004 Mitsubishi Endeavor Limited
2004 STARTING & CHARGING SYSTEMS Generators & Regulators - Endeavor

See REGULATOR VOLTAGE SPECIFICATIONS TABLE
.
14. After the test, lower the engine speed to idle.
15. Turn the ignition switch to the LOCK (OFF) position.
16. Disconnect the engine tachometer or scan tool MB991958.
17. Disconnect the negative battery cable.
18. Disconnect the ammeter and voltmeter.
19. Connect the negative battery cable.
20. Run the engine for 10 minutes at an idle.
REGULATOR VOLTAGE SPECIFICATIONS
WAVE PATTERN CHECK USING AN OSCILLOSCOPE Abnormal Waveforms The size of the waveform patterns can differ greatly, depending on the adjustment
of the variable knob on the oscilloscope. See Fig. 6
.
Identification of abnormal waveforms is easier when there is a large output current
(regulator is not operating). Waveforms can be observed when the headlights are
illuminated.
Check the conditions of the generator malfunction light (illuminated/not
illuminated
) also, and carr
y out a total check.
Ambient Temp. °F (°C)
Voltage
Terminal S-4 (-20)
14.2-15.4
68 (20)
13.9-14.9
140 (60)
13.4-14.5
176 (80)
13.1-14.2

2004 Mitsubishi Endeavor Limited
2004 STARTING & CHARGING SYSTEMS Generators & Regulators - Endeavor

Fig. 134: Installing Connecting Rod Cap Nu
t
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
INSPECTION PISTON Replace the piston if scratches or seizure is evident on its surfaces (especially the
thrust surface). Replace the piston if it is cracked. PISTON PIN 1. Insert the piston pin into the piston pin hole with a thumb. You should feel a
slight resistance. Replace the piston pin if it can be easily inserted or there is
excessive play.
2. The piston and piston pin must be replaced as an assembly. PISTON RING 1. Check the piston ring for damage, excessive wear, and breakage. Replace if
defects are evident. If the piston has been replaced with a new one, the piston
rings must also be replaced with new ones.
2. Check for clearance between the piston ring and ring groove. If the limit is
exceeded, replace the ring or piston, or both.
Standard Value:
Number 1: 0.03 - 0.07 mm (0.0012 - 0.0027 inch)
Number 2: 0.02 - 0.06 mm (0.0008 - 0.0023 inch)
Limit: 0.1 mm (0.003 inch)
2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor

Required Special Tool
:
MB991958: Scan Tool (MUT-III Sub Assembly)
MB991824: V.C.I. MB991827: MUT-III USB Cable MB991910: MUT-III Main Harness A
1. Before checks set the vehicle in the following condition:
Engine coolant temperature: 80 - 95°C (176 - 203°F) Lights and all accessories: OFF Transaxle: P range
2. Connect scan tool MB991958 to the data link connec
tor.
NOTE: Vehicles for Canada, the headlight, taillight, etc. remain
lit even when the lighting switch is in "OFF" position
but this is no problem for checks.
CAUTION: To prevent damage to scan tool MB991958,
always turn the ignition switch to the
"LOCK" (OFF) position before connecting or
disconnecting scan tool MB991958.

2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor