2004 MITSUBISHI ENDEAVOR belt

Fig. 4: Checking Cap Valve Opening Pressure

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Q: Does the reading remain at or above the minimum limit?
YES: Go to Step 3.
NO: Replace the radiator cap. Then go to Step 5 .
STEP 3. Check thermostat operation.
Refer to INSPECTION
.
Q: Does the thermostat operate correctly?
YES: Go to Step 4.
NO: Replace the thermostat, then go to Step 5 .
STEP 4. Check the drive belt for slippage or damage.

2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Cooling - Endeavor

Refer to 7. DRIVE BELTS (FOR GENERATOR, POWER STEERIN
G .
Q: Is the drive belt loose or damaged?
YES: Adjust or replace the drive belt, then go to Step 5.
NO: There is no action to be taken.
STEP 5. Retest the system.
Check the engine coolant temperature.
Q: Is the engine coolant temperature abnormally high?
YES: Return to Step 2 .
NO: The procedure is complete.
INSPECTION PROCEDURE 3: Radiator Fan and Condenser Fan do not Operate
2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Cooling - Endeavor

Fig. 1: Charging System Circuit Diagram (Up To December 2003)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Fig. 2: Charging System Circuit Diagram (From January 2004)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
ADJUSTMENTS BELT TENSION
2004 Mitsubishi Endeavor Limited
2004 STARTING & CHARGING SYSTEMS Generators & Regulators - 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

Fig. 3: Generator Output Line Voltage Drop Test (Typical)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
1. Always be sure to check following before testing:
Generator installation. Generator drive belt tension. Fusible link. Abnormal noise form generator while engine is running.
2. Tune ignition switch to LOCK (OFF) position.
3. Disconnect ne
gative batter
y cable.
WARNING:Battery posts, terminals and related accessories
contain lead and lead compounds. Wash hands
after handling.

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

Battery. 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. Connect a clamp-type DC test ammeter with a range of 0-150A to the
generator B terminal output wire.
5. Connect a voltmeter with a range of 0-20V between the generator B terminal
and ground. (Connect the positive lead of the voltmeter to the B terminal, and
then connect the negative lead of the voltmeter to ground.)
6. Connect the negative battery cable.
7. Connect an engine tachometer or scan tool MB991958.
8. Leave the hood open.
9. Check to be sure that the reading on the voltmeter is equal to the battery
positive voltage.
10. After turnin
g on the headli
ghts, start the en
gine.
WARNING:Never use clips to connect the line. Loose
connections (for example, using clips) will lead
to a serious accident because of high current.
NOTE: If the voltage is 0 V, the cause is probably an open
circuit in the wire or fusible link between the generator
B terminal and the battery positive terminal or
malfunctioning voltmeter.
NOTE: Because the current from the battery will soon drop
after the engine is started, the next step should be
carried out as quickly as possible in order to obtain the
maximum current output value.

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

Fig. 2: Identifying Special Tools Specification Chart (2 Of 2)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
GENERATOR AND DRIVE BELT REMOVAL AND INSTALLATION
2004 Mitsubishi Endeavor Limited 2004 ENGINE Engine Overhaul - Endeavor