2004 MITSUBISHI ENDEAVOR light

Fig. 4: Output Current Test

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
1. Before the test, always be sure to check the following.
Generator installation.
WARNING:Battery posts, terminals and related accessories
contain lead and lead compounds. Wash hands
after handling.
NOTE: The battery to be used should be slightly
discharged. The load in a fully-charged battery will
be insufficient and the test may not be able to be
carried out correctly.

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. 26: Install The Timing Belt On Each Sprocket And Pulley

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
7. Install special tool MD998767 to the tensioner pulley. While pushing the
pulley lightly against the belt using the special tool, tighten the flange bolt.
Tightening torque: 48+/-6 N.m (35+/-4 ft-lb)

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - 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

(Ignition Timing Check)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3. Set up a timing light.
4. Start the engine and run it at idle.
5. Check that the idle speed is approximately 680 r/min.
6. Select scan tool MB991958 actuator test "item number 17".
7. Check that basic ignition timing is within the standard value.
Standard value: 5° BTDC +/-3°
8. If the basic ignition timing is not within the standard value, check the
following items:
Diagnostic output Timing belt cover and crankshaft position sensor installation conditions Crankshaft sensing blade condition
9. Press the clear key on scan tool MB991958 (select forced drive stop mode),
and cancel the actuator test.
10. Check that the actual ignition timing is at the standard value.
Standard value: Approximately 10° BTDC
CURB IDLE SPEED CHECK Required Special Tool:
CAUTION: If the actuator test is not canceled, the forced
drive will continue for 27 minutes. Driving in this
state could lead to engine failure.
NOTE: Ignition timing fluctuates about+/-7° Before T op Dead
Center, even under normal operating condition.
NOTE: It is automatically further advanced by about 5° to 10°
Before Top Dead Center at higher altitudes.

2004 Mitsubishi Endeavor Limited
2004 ENGINE Engine - Endeavor