Page 1
Page 1131
Application Table Part 2
Page 2
Page 559
Power Steering Pressure Switch: Locations
Overall View
View A
Page 3
Page 5625
Install while aligning with the amplifier mounting hole.
Page 4
Page 3472
POSITION OF THE PROP SHAFT. IT WILL DAMAGE THE OIL SEAL.
Install the new bolt only hand-tight, positioning the flat side of the new nut toward the center of the
hub, and then tighten to 40 - 45 Nm (30 - 33 ft/lb). DO NOT OVERTORQUE.
Hold a wrench on the nut to prevent the prop shaft from rotating during tightening.
d. Repeat Steps a. through c. for the other three bolts. Remove and replace the bolts one at a time.
e. Retorque each bolt in the same order. Then mark each bolt with paint.
PARTS INFORMATION
Use the Genuine Mitsubishi Parts shown
Page 5
WARRANTY INFORMATION
Page 6
Page 5586
Use scan tool MB991958 to diagnose the CAN bus lines.
1. Connect scan tool MB991958 to the data link connector. 2. Turn the ignition switch to "ON"
position. 3. Diagnose the CAN bus line.
Q: Is the check result satisfactory?
YES : Go to Step 2.
NO : Repair the CAN bus lines (Refer to Diagnosis or ). See: Powertrain Management/Computers
and Control Systems/Information Bus/Testing and Inspection/Component Tests and General
Diagnostics
After diagnosing the CAN bus lines, go to Step 3.
STEP 2. Using scan tool MB991958, read the A/C diagnostic trouble code.
Check if an A/C system DTC is set.
Q: Is the DTC set?
Page 7
YES : Refer to Manual A/C Diagnosis - Diagnostic Trouble Code See: Heating and Air
Conditioning/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures
or
Auto A/C Diagnosis - Diagnostic Trouble Code See: Heating and Air Conditioning/Testing and
Inspection
and then go to Step 3.
NO : Replace multi-center display unit (middle grade type) and then go to Step 3.
STEP 3. Retest the system
Check if the ambient air temperature operation screen is displayed normally.
Q: Is the check result satisfactory?
YES : The procedure is complete.
NO : Go to Step 1.
Inspection Procedure 6
Page 8
Page 4498
Page 9
Fuses 1-24 (2 Of 2)
Page 10
Page 6979
Page 11
Service and Repair
Page 12
Fuel Pressure Release: Service and Repair
Page 13
FUEL PUMP CONNECTOR DISCONNECTION (HOW TO REDUCE PRESSURIZED FUEL
LINES)
WARNING: When removing the fuel pipe, etc., release fuel pressure to prevent fuel spray.
1. Remove the left rear seat cushion mounting bolts, and lift the left rear seat cushion to tie it to the
head restraint.
2. Cut the floor mat and then remove the service hole cover to gain access to the service hole.
NOTE: Push the floor mat to find the notches and cut the floor mat along them.
3. Disconnect the fuel pump module connector. 4. After starting the engine and letting it run until it
stops naturally, turn the ignition switch to the "LOCK" (OFF) position. 5. Connect the fuel pump
module connector.
6. Install the service hole cover.
Page 14
Page 3163
Page 15
DO NOT DISTURB THE HARNESS CABLES OR CONNECTIONS. INTERRUPTION DURING
THE PROGRAMMING PROCESS COULD CAUSE THE PCM TO LOSE DATA OR PREVENT
Page 16
FUTURE PCM REPROGRAMMING.
c.Select MFI and click on the check mark.
d.The CAN database screen will display, if the appropriate flash data is found. (If more than one
row is displayed in the table, select the appropriate ECU part number.) Click on the check mark. It
will take up to 10 minutes to complete the reprogramming.
Page 17
Page 5848
>>A<< DOOR CHECK INSTALLATION
Install the door check so that the identification mark faces upwards.
>>B<< LOWER SASH INSTALLATION
Securely insert the lower sash into the window rear sash.
Page 18
Built Before December 2003
Ignition Switch: Service and Repair Built Before December 2003
IGNITION SWITCH
REMOVAL AND INSTALLATION
REMOVAL SERVICE POINTS
Page 5243
Page 19
1. Check that there is no connector damage, bent terminals or harness crimping. 2. Check the
installation of the seat slide sensor.
Page 20
OCCUPANT CLASSIFICATION SENSOR (VEHICLES WITH ADVANCED AIR BAG)
1. Check the occupant classification-ECU case and occupant classification sensor for dents, cracks
or deformation. 2. Check the connector for damage, and the terminals for deformation. 3. Check
the installation of the occupant classification-ECU and occupant classification sensor.
STEERING WHEEL, STEERING COLUMN AND SHAFT ASSEMBLY
1. Check the wiring harness (built into the steering wheel) and the connectors for damage, and the
terminals for deformation. 2. Install the air bag module to check fit or alignment with the steering
wheel. 3. Check the steering wheel for noise, binding or difficult operation and excessive free play.
4. Check the steering column shaft shock absorbing mechanism (Refer to Powertrain
Management/Computers and Control Systems/Information
Bus/Service and Repair - Steering Column Shaft Assembly Shock Absorbing Mechanism Check).
SEAT BELT WITH PRE-TENSIONER
1. Check the seat belt for damage or deformation. 2. Check the seat belt with pre-tensioner for
cracks or deformation. 3. Check that the unit is installed correctly to the vehicle body.
HARNESS CONNECTOR (FRONT WIRING HARNESS, INSTRUMENT PANEL WIRING
HARNESS, AND FLOOR WIRING HARNESS)
Check the harnesses for binding, the connectors for damage, poor connection, and the terminals
for deformation (Refer to SRS Service Precautions).
Page 21
Page 6573
Driver/Vehicle Information Display: Symptom Related Diagnostic Procedures
Symptom Index
SYMPTOM CHART
Symptom Chart
CAUTION: During diagnosis, a DTC code associated with other system may be set when the
ignition switch is turned on with connector(s) disconnected. On completion, confirm all systems for
DTC code(s). If DTC code(s) are set, erase them all.
Inspection Procedure 1
Communication with Scan Tool Is not Possible. (Middle Grade Type)
Page 22
Page 1368
Lifter / Lash Adjuster: Technical Service Bulletins Engine - Valve Lash Adjuster Cleaning
Procedure
NO: TSB-99-11-006 DATE: June, 1999 MODEL: See below
SUBJECT: VALVE LASH ADJUSTER CLEANING
PURPOSE
Page 23
This bulletin contains cleaning procedures for valve lash adjusters. In many cases, cleaning valve
lash adjusters can extend their service life. Mitsubishi Motors strongly suggests cleaning and
inspecting lash adjusters before considering lash adjuster replacement.
AFFECTED VEHICLES
All models equipped with valve lash adjusters
PROCEDURE
! CAUTION
A Valve lash adjusters are precision mechanisms. Do not allow them to become contaminated by
dirt or other foreign substances. Do not attempt to disassemble valve lash adjusters. Use only
clean diesel fuel to clean valve lash adjusters.
1. Prepare three containers. Place enough diesel fuel into each container to cover a lash adjuster
when it is standing upright.
^ Container A will be used to clean the outside of the lash adjuster.
^ Container B will be used to clean the inside of the lash adjuster.
^ After cleaning the adjuster, use Container C to fill it with clean diesel fuel.
2. Place the lash adjuster into container A and clean its outside surface, using a nylon brush if
necessary.
Page 24
Page 1129
Fuse: Application and ID Centralized Junction (Built After January 2004)
Page 25
Locations
Page 26
Locations
Leak Detection Solenoid: Locations
Overall View
Page 27
View E
Page 28
Page 7283
Page 29
Page 5540
Page 30
If an abnormal voltage or temperature is detected, the multi-center display unit will sound its buzzer
to indicate this and activate a message to blank the screen in approximately seven seconds.
Page 31
NOTE: The unit blanks the screen immediately when the power supply voltage reaches 18 volts.
Fail-safe function is deactivated when:
Power supply voltage is abnormal
- The fail-safe function will be deactivated if the power supply voltage remains 10 volts or more for
approximately five seconds, or the ignition switch is turned to the "LOCK" (OFF) position.
- The fail-safe function will be deactivated if the power supply voltage remains 17 volts or less for
approximately five seconds or more, or the ignition switch is turned to the "LOCK" (OFF) position.
Abnormally high temperature is detected in the unit.
- The fail-safe function will be deactivated if its internal temperature has reduced to 85 °C (185 °F)
or less, or the ignition switch is turned to the "LOCK" (OFF) position.
Page 32
Page 5846
Page 33
Rear Door Interior Handle: Service and Repair
DOOR HANDLE AND LATCH
Part 1
Page 34
Page 3889
Page 35
number 3. Standard Value: 3.4 - 3.6 Volts
Page 36
4. If the voltage deviates from the standard value, check the power supply wire and ground wire. If
no problems are found, replace the G-sensor.
Page 37
Page 3121
2004 Endeavor service manual, page 00-43 and 2005 Endeavor service manual, page 00-46.
Page 38
Front Impact Sensor
Impact Sensor: Service and Repair Front Impact Sensor
Vehicles Without Advanced Air Bag
FRONT IMPACT SENSORS
REMOVAL AND INSTALLATION
WARNING:
- Never repair or disassemble the front impact sensor. If faulty, replace it.
- Handle the front impact sensors very carefully, taking care not to drop them. They must be
replaced if they are dropped.
- Replace the sensors with new ones after the air bag has deployed.
REMOVAL SERVICE POINT
[[A]] NEGATIVE (-) BATTERY CABLE DISCONNECTION
Page 39
DANGER: Wait at least 60 seconds after disconnecting the battery cable before doing any further
work (Refer to Service Precautions).
WARNING: Battery posts, terminals and related accessories contain lead and lead compounds.
WASH HANDS AFTER HANDLING.
Page 40
Anti-Lock Braking System (ABS)
Page 41
Specifications
Page 42
Valve Clearance: Specifications
Page 43
Engine overhaul
Valve thickness to valve guide clearance
Intake
Standard value
............................................................................................................................................. 0.02 -
0.05 mm (0.0008 - 0.0019 in.) Limit .....................................................................................................
.................................................................................. 0.10 mm (0.003 in.)
Exhaust
Standard value
............................................................................................................................................. 0.04 -
0.06 mm (0.0016 - 0.0023 in.) Limit .....................................................................................................
.................................................................................. 0.15 mm (0.005 in.)
Page 44
Page 9
Alarm Module: Locations Built After January 2004
Page 45
Overall View
View G
Page 46
Page 650
Page 47
STEP 7. Check the harness wire between immobilizer-ECU connector C-310-1 (terminal 4) and
ground.
Page 48
NOTE: Also check key reminder switch connector C-310 for loose, corroded, or damaged
terminals, or terminals pushed back in the connector. If key reminder switch connector C-310 is
damaged, Repair or replace it. Refer to Harness Connector Inspection.
Q: Is the harness wire between immobilizer-ECU connector C-310-1 (terminal 4) and ground in
good condition?
YES : There is no action to be taken.
NO : Repair or replace the damaged component(s). Confirm that scan tool MB991958
communicates normally.
STEP 8. Check immobilizer-ECU connector C-310-1 and PCM connector B-18 for loose, corroded
or damaged terminals, or terminal pushed back in the connector.
Q: Are immobilizer-ECU connector C-310-1 and PCM connector B-18 in good condition?
YES : Go to Step 9.
Page 49
Page 3400
View P
Overall View
Page 50
Overall View
Page 51
Specifications
Page 52
Idle Speed: Specifications
Page 53
SERVICE SPECIFICATIONS
ITEM.....................................................................................................................................................
..............................................STANDARD VALUE
Idle speed.............................................................................................................................................
............................................................ 680 ± 50 r/min
Idle-up speed At low pressure..............................................................................................................
....................................................................................680 ± 50 r/min At middle pressure...................
..............................................................................................................................................................
............730 ± 50 r/min At high pressure...............................................................................................
..................................................................................................750 ± 50 r/min
Page 54
Page 4499
Page 55
Fuses 1-26 (1 Of 3)
Page 56
Page 5299
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.
3. Connect scan tool MB991958 to the data link connector. 4. Turn the ignition switch to the "ON"
position. 5. Check DTCs using scan tool MB991958 to ensure entire SRS operates properly.
At this time, check that no DTC except 21 and 24 are set.
DANGER: Wait at least 60 seconds after disconnecting the battery cable before doing any further
work. (Refer to Service Precautions).
WARNING: Battery posts, terminals and related accessories contain lead and lead compounds.
WASH HANDS AFTER HANDLING.
6. Turn the ignition switch to the "LOCK" (OFF) position. Disconnect the negative (-) battery cable
and tape the terminal to prevent accidental
connection and air bags deployment.
]]B[[ CLOCK SPRING INSTALLATION
Page 57
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.
The content of this article reflects the changes identified in TSB-08-52B-001
A modified clock spring has been adopted for Service Parts on affected vehicles as of September
2007. New and old style parts are interchangeable. This TSB advises the procedures for alignment
of the neutral point of the new clock spring when a part is replaced.
Parts Identification
Page 58
Page 3782
11. If the result of inspection is abnormal, repair according to the Diagnosis Table provided. 12.
After inspection, disconnect scan tool MB991958 immediately after turning the ignition switch to the
"LOCK" (OFF) position.
Page 59
Page 678
Page 60
Built After January 2004
Page 61
INSPECTION
IGNITION SWITCH CONTINUITY CHECK
Disconnect ignition switch connector C-308 without removing the ignition switch and steering lock
cylinder. Then check the continuity.
KEY REMINDER SWITCH CHECK
Disconnect key reminder switch connector C-312 without removing the key reminder switch and
steering lock cylinder.
KEY REMINDER SWITCH CHECK
Check for continuity between terminal 4 and terminal 6.
Page 62
Service and Repair
Headlamp Bulb: Service and Repair
BULB REPLACEMENT
HEADLIGHT BULB
1. Disconnect the headlight connector. 2. Remove the socket cover with the bulb by twisting it
counterclockwise as shown.
CAUTION: Do not touch the surface of the bulb with hands or dirty gloves as the bulb may fail after
a short time. If the surface does become dirty, clean it with alcohol or thinner, and let it dry
thoroughly before installing.
3. Install a new socket cover with bulb to the headlight by twisting it clockwise.
Page 63
Service and Repair
Page 64
Fuel Pressure Release: Service and Repair
Page 65
FUEL PUMP CONNECTOR DISCONNECTION (HOW TO REDUCE PRESSURIZED FUEL
LINES)
WARNING: When removing the fuel pipe, etc., release fuel pressure to prevent fuel spray.
1. Remove the left rear seat cushion mounting bolts, and lift the left rear seat cushion to tie it to the
head restraint.
2. Cut the floor mat and then remove the service hole cover to gain access to the service hole.
NOTE: Push the floor mat to find the notches and cut the floor mat along them.
3. Disconnect the fuel pump module connector. 4. After starting the engine and letting it run until it
stops naturally, turn the ignition switch to the "LOCK" (OFF) position. 5. Connect the fuel pump
module connector.
6. Install the service hole cover.
Page 66
Page 2526
Throttle Position Sensor: Locations Built After January 2004
Page 67
View E
Overall View
Overall View
Page 68
A/C - Heat From Vents, Manual A/C System
Page 69
Cabin Ventilation Duct: Technical Service Bulletins A/C - Heat From Vents, Manual A/C System
Page 70
SOURCE: Mitsubishi Tech Talk Article
TITLE: HEAT FROM VENTS - MANUAL A/C SYSTEM
APPLIES TO: 2004 Endeavor
SERVICE TIP:
Warm air may come out of the vents if the temperature knob is set between the detents for MAX
A/C and full cold. If you get this complaint, confirm the knob setting, then instruct the customer to
make sure the knob is turned to either of the positions, but not in between.
Page 71
Page 4945
Part 2
Page 72
Testing and Inspection
Page 73
Air Bag: Testing and Inspection
Page 74
AIR BAG MODULE CHECK
DANGER: Never attempt to measure the circuit resistance of the air bag modules (squib), even if
you are using the specified tester. If the circuit resistance is measured with a tester, accidental air
bag deployment will result, and possible serious personal injury.
WARNING: If any component damage is found during the following inspection, replace the air bag
module with a new one. Dispose of the old one according to the specified procedure. (Refer to Air
Bag Module And Seat Belt Pre-tensioner Disposal Procedures).
1. Check the pad cover for dents, cracks or deformation.
2. Check the connectors for damage, the terminals for deformation, and the harness for binding. 3.
Check the air bag inflator case for dents, cracks or deformation. 4. Install the air bag module
(driver's side) to the steering wheel and check fit and alignment with the steering wheel. 5. Install
the air bag module (front passenger's side) to the instrument panel and front deck crossmember
and check fit and alignment.
FRONT SEATBACK ASSEMBLY WITH SIDE-AIRBAG MODULE CHECK
Page 75
Page 1619
Page 76
Water Pump: Specifications
Page 77
Engine Overhaul
Water pump and water pipes
Engine coolant temperature sensor
................................................................................................................................... 29 ± 10 Nm (22
± 7 ft. lbs.)
Engine Cooling
Water pump bolt
M10 ......................................................................................................................................................
.............................. 24 ± 3 Nm (17 ± 2 ft. lbs.) M8 ...............................................................................
....................................................................................................... 42 ± 8 Nm (31 ± 6 ft. lbs.)
Page 78
Page 102
Page 79
Fuses 1-24 (2 Of 2)
Page 80
Page 2870
Page 81
After all components are installed, connect the MUT-III scan tool and run the Evap Leak Monitor to
check for fuel/vapor leaks:
Page 82
System Select --> MFI main screen --> Mitsubishi --> Emission Test --> Evap Leak Monitor
Follow the on-screen instructions. Check for DTCs when completed.
^ If the fuel filler pipe is NOT perforated, fuel filler pipe replacement under this warranty extension
does not apply. Refer to the flowchart.
2. If the customer reports the MIL on:
a. Connect the MUT-III scan tool and check the Diagnostic Trouble Codes (DTCs).
b. If DTC P0442, P0455 or P0456 (for evaporative emissions control system leak) is set, remove
the fuel filler pipe protector and inspect for perforation of the fuel filler pipe.
^ If the pipe is NOT perforated, refer to the flowchart.
^ If the pipe is perforated, replace the pipe, then run the Evap Leak Monitor to check for fuel/vapor
leaks:
System Select --> MFI main screen --> Mitsubishi --> Emission Test --> Evap Leak Monitor
Follow the on-screen instructions.
c. If a DTC other than P0442, P0455 or P0456 is set, refer to the flowchart.
PARTS INFORMATION
Page 83
Service and Repair
Remote Switch: Service and Repair
REMOVAL AND INSTALLATION
WARNING:
- Before removing the air bag module, refer to Service Precautions and Air Bag Module and Clock
Spring ( or ).
- When removing and installing the steering wheel, do not let it bump against the air bag module.
REMOVAL SERVICE POINT
Page 3578
Page 84
Transmission Temperature Sensor/Switch: Locations Built After January 2004
View P
Overall View
Overall View
Page 85
Page 2997
Page 86
Page 6516
Page 87
Page 7111
Page 88
Taillight, Position Light And License Plate Light Part 4
Page 89
Built Before December 2003
Accelerator Pedal Position Sensor: Locations Built Before December 2003
View S
Page 90
Overall View
Overall View
Page 91
Page 518
View T
Page 92
Overall View
Overall View
Page 93
Page 3942
Page 94
NOTE:
Page 95
Due to the number of applicable service manuals that this TSB applies to the individual page
numbers are not provided. Apply this TSB using the Group No. and Title as described.
Page 96
Page 4202
Application Table (part 2)
Page 97
Page 3692
Page 98
NOTE: rear ABS rotors (FWD) are integrated with the rear hub assembly and cannot be
disassembled.
Page 99
REMOVAL SERVICE POINT
Page 4621
Power Steering Fluid: Service and Repair Power Steering System Air Bleeding
POWER STEERING SYSTEM AIR BLEEDING
Perform air bleeding procedure as necessary after replacing the steering gear, oil pump or the
steering fluid lines. 1. Raise and support the front wheels. 2. Disconnect the ignition coil
connectors.
CAUTION: Perform air bleeding only while cranking the engine. Do not perform air bleeding while
the engine is running. If you do so, air in the fluid will be increased and air bleeding will become
more difficult. During air bleeding, refill the steering fluid so that the level never falls below the
lower mark on the dipstick.
3. Turn the steering wheel all the way to the left and right five or six times while using the starter
motor to crank the engine intermittently several
times (for 15 to 20 seconds).
4. Connect the ignition coil connectors. 5. Start the engine and allow to idle. 6. Turn the steering
wheel to the left and right until there are no air bubbles in the oil reservoir. 7. Confirm that the fluid
is not milky, and that the level is between the high and low dipstick marks. 8. Confirm that there is
very little change in the fluid level when the steering wheel is turned left and right.
CAUTION: If the fluid level rises suddenly after the engine is stopped, the air has not been
completely bled. If air bleeding is not complete, there will be abnormal noises from the pump and
the flow-control valve, and this condition could reduce the life of the power steering components.
9. Confirm that the change in the fluid level is no more than 5 mm (0.2 inch) when the engine is
stopped.
10. If the change of the fluid level is 5 mm (0.2 inch) or more, the air has not been completely bled
from the system. The air bleeding procedure must
be repeated.
Page 100
Page 3347
SUBJECT: KEY INTERLOCK CABLE ADJUSTMENT
PARTS INFORMATION
WARRANTY INFORMATION
This bulletin is supplied as technical information only and is not an authorization to repair. If an
affected vehicle is reported with the described condition diagnose the condition repair as described
in this bulletin and submit a normal warranty claim.
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