clock MITSUBISHI ENDEAVOR 2004 Service Repair Manual

Observe these precautions when servicing the air bag system:
Disable SRS before servicing any SRS component. Failure to do this may
result in accidental air bag deployment and possible personal injury. See DISABLING & ACTIVATING AIR BAG SYSTEM
.
After disabling SRS, wait at least 60 seconds before servicing SRS. After servicing, always turn ignition on from outside of vehicle in case of
accidental air bag module deployment. After servicing, check AIR BAG warning light to verify system operation. See SYSTEM OPERATION CHECK
.
Always wear safety glasses when servicing or handling an SRS component. Hearing protection must be worn when performing deployment procedures. DO NOT expose air bag modules, clockspring or SRS ECU to temperatures
greater than 200°F (93°C ). DO NOT expose seat belt pretensioners to temperatures greater than 194°F
(90°C ). When placing a live air bag module on a bench or other surface, always place
air bag module with trim cover facing up and away from surface. This will
reduce motion of air bag module if accidental deployment occurs. After air bag module deploys, surrounding surfaces may contain deposits of
sodium hydroxide, which irritates skin. Always wear safety glasses, rubber
gloves and a long-sleeved shirt during clean-up. Wash hands using mild soap
and water. Follow correct clean-up and disposal procedures. See
DISPOSAL
PROCEDURES
.
Because of critical system operating requirements, DO NOT service any SRS
components. Repairs are only made by replacing defective components. DO NOT allow any electrical source near inflator on back of air bag module. When carrying a live (undeployed) air bag module, trim cover must be pointed
away from body to minimize injury in case of accidental air bag deployment. If instructed to probe wire harness, do so from harness side of connector. DO NOT probe a wire through insulator. Wire will be damaged and eventually
fail due to corrosion. When
performin
g electrical tests,
prevent accidental shortin
g of terminals.

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

On-vehicle Deployment 1. Before proceeding, see
AIR BAG SAFETY PRECAUTIONS
. Move vehicle
to an isolated area. Open all doors and windows. Disconnect and shield
negative battery cable end. Disconnect positive battery cable. Remove battery
from vehicle. Wait at least 60 seconds before continuing.
2. To deploy driver-side air bag module, remove steering column lower cover.
Disconnect lower clockspring Yellow 4-pin connector. Cut harness side of
connector from wire harness and strip ends of driver-side air bag module wires
on harness side of clockspring connector. See
WIRING DIAGRAMS
.
3. To deploy passenger-side air bag module, remove glove box and glove box
outer case. Disconnect passenger-side air bag module Red connector.
4. To deploy side impact air bag module, disconnect appropriate side impact air
bag module Red connector, located under front seat.
5. To deploy seat belt pretensioner, disconnect appropriate seat belt pretensioner
connector, located at seat belt pretensioner.
6. Fabricate a de
ployment harness usin
g two wires at least 20 feet
(6.1 m
) in
WARNING:Air bag modules and seat belt pretensioners make
loud noises during deployment. Air bag module and
seat belt pretensioner deployment could cause
personal injury. Always deploy components
outdoors and away from people. Never deploy air
bag modules with trim cover face down.
NOTE: If vehicle is to be scrapped, perform On-vehicle
deployment. See ON
-VEHICLE DEPLOYMENT
. If vehicle
will continue to be operated, perform Off-vehicle
Deployment. See OFF
-VEHICLE DEPLOYMENT
.
NOTE: Driver-side and passenger-side air bag modules will be
either single-stage or dual-stage. Consult wiring
diagrams to ensure correct wires are cut and spliced
prior to deployment. See WIRING DIAGRAMS
.

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

length. Strip insulation from ends of wires. Connect wires at one end of harness
to clockspring connector stripped wires and cover connections with insulating
tape. Temporarily wrap other end of harness wires together to prevent
unexpected air bag deployment.
7. Stretch deployment harness as far away from vehicle as possible. Roll up
vehicle windows to lessen deployment noise and cover vehicle with car cover,
in case glass should shatter during deployment. Ensure area is clear of people.
Untwist deployment harness wire ends. Touch wire ends to 12 volt battery
terminals to deploy driver-side air bag module.
8. Repeat procedure for remaining air bag modules and seat belt pretensioners.
Use SRS Air Bag Adapter Harness (MB686560) for passenger-side and side
impact air bag modules. Use SRS Adapter Harness (MR991885) for seat belt
pretensioners. If any component fails to deploy, stay away from vehicle and
contact manufacturer for further instructions. Allow 30 minutes for air bag
modules to cool.
Off-vehicle Deployment 1. Before proceeding, see
AIR BAG SAFETY PRECAUTIONS
. Turn ignition
switch to LOCK position. Disconnect negative battery cable. Shield cable end.
Wait at least 60 seconds before continuing. Disconnect positive battery cable.
Remove battery from vehicle.
2. Fabricate a deployment harness using two wires at least 20 feet (6.1 m) in
length. Strip insulation from ends of wires. Twist together one end of wires
temporarily. Remove driver-side air bag module. See
DRIVER
-SIDE AIR
BAG MODULE & CLOCKSPRING
under REMOVAL &
INSTALLATION. Place driver-side air bag module on surface face up. Touch
vehicle body with bare hands to discharge static electricity from body. Cut
driver-side air bag module connector from pigtail leads. Strip insulation from
ends of
pigtail wires. Attach remainin
g ends of de
ployment harness to
pigtail NOTE: Driver-side and passenger-side air bag modules will be
either single-stage or dual-stage. Consult wiring
diagrams to ensure correct wires are cut and spliced
prior to deployment. See WIRING DIAGRAMS
.

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

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

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

ADJUSTMENTS CENTERING CLOCKSPRING (DUAL-STAGE AIR BAG SYSTEM) Turn clockspring fully clockwise, then turn counterclockwise about 3 turns to align
mating marks. See Fig. 17
. Clockspring is now centered.
Fig. 17: Aligning Clockspring Mating Marks (Single
-sta
ge Clocks
prin
g Shown,
Dual
-stage Clockspring Is Similar)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
WIRE REPAIR DO NOT repair SRS wiring harness or connectors. If SRS wiring or harness
connectors are faulty, replace wiring harness. TORQUE SPECIFICATION
S

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

TORQUE SPECIFICATIONS DIAGNOSTICS INITIAL SRS DIAGNOSTIC PROCEDURE (DUAL-STAGE AIR BAG SYSTEM) Application
Ft. Lbs. (N.m)
Front seatBack bolts
25-40 (34-54)
Bolts
25-40 (34-54)
Nuts
18-26 (24-35)
Seat belt pretensioner anchor bolts
24-40 (33-54)
Steering wheel nut
24-36 (33-49)
INCH Lbs. (N.m)
Clockspring screws
5-7 (0.56-0.79)
Driver-side air bag module bolts
62-97 (7.0-11.0
Front impact sensor nuts
44-89 (5.0-10.0)
Passenger-side air bag module bolts
(1)
Seat slide sensor bolt
35-53 (4.0-6.0)
Side impact sensor nuts
44-89 (5.0-10.0)
SRS ECUBracket nuts
44-89 (5.0-10.0)
Nuts
44-89 (5.0-10.0)
(1)
Information is not available.
WARNING:Accidental air bag deployment is possible. Personal
in
jury ma
y result. Follow air ba
g service precautions
to prevent accidental air bag deployment and
personal injury. See AIR BAG SAFETY
PRECAUTIONS
.
NOTE: AIR BAG warning light will come on if battery voltage is
low. Ensure battery is fully charged. When battery voltage
is restored to normal, AIR BAG warning light will go out.

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