2004 MITSUBISHI ENDEAVOR stop start

2004 STARTING & CHARGING SYSTEMS
Starters - Endeavor
DESCRIPTION & OPERATION If the ignition switch is turned to START position, current flows in the coil
provided inside magnetic switch, attracting the plunger. When plunger is attracted,
the lever connected to plunger is actuated to engage starter clutch. On the other
hand, attracting plunger will turn on magnetic switch, allowing "B" terminal and
"M" terminal to conduct. Thus, current flows to engage starter motor. When
ignition switch is returned to ON position after starting engine, starter clutch is
disengaged from ring gear.
An overrunning clutch is provided between pinion and armature shaft to prevent
damage to starter.
When the ignition switch is switched to the START position while the selector leve
r
is at the "P" or "N" range, the contact (magnetic switch) of the starter is switched
ON and the starter motor is activated.
ADJUSTMENT PINION GAP 1. Disconnect the field coil wire from the "M" terminal of magnetic switch.
2. Connect a 12V battery between "S" terminal and "M" terminal. See Fig. 1
.
3. Set switch to ON and pinion will move out.
4. Check the pinion to stopper clearance (pinion gap) with a feeler gauge. See
Fig. 2
.
5. If the pinion gap is out of specification, adjust by adding or removing gasket(s)
between the ma
gnetic switch and front bracket. CAUTION: To prevent coil from burning, DO NOT apply voltage
to starter assembly for more than 10 seconds.

2004 Mitsubishi Endeavor Limited
2004 STARTING & CHARGING SYSTEMS Starters - Endeavor


2004 Mitsubishi Endeavor Limited
2004 STARTING & CHARGING SYSTEMS Starters - Endeavor

STARTER MOTOR DOES NOT STOPCheck the magnetic switch. ON-VEHICLE TESTING STARTER MOTOR DOES NOT OPERATE 1. Is the battery in good condition? If Yes, go to the next step. If No, then charge
or replace battery.
2. Disconnect the starter motor "S" (solenoid) terminal connector. Using a jumper
wire, apply battery positive voltage to starter motor "S" (solenoid) terminal.
Does starter motor operate normally? If Yes, then check ignition switch,
transmission range switch and the line between the battery and starter motor
"S" (solenoid) terminal. If No, then go to the next step.
3. Check if the cable between starter "B" (battery) terminal and battery positive
terminal for connection and continuity. Is the starter cable in good condition? I
f
Yes, then go to the next step. If No, then repair or replace the cable.
4. Check the connection and continuity of the cable between starter motor body
and the negative battery terminal. Is the ground line in good condition? If Yes,
then go to the next step. If No, then repair or replace cable.
5. Is the starter motor in good condition? If Yes, problem is excessive rotational
resistance of the engine. If No, then replace the starter motor.
BENCH TESTING MAGNETIC SWITCH PULL-IN TEST 1. Disconnect field coil wire from "M" terminal of the magnetic switch. See Fig.
3 . WARNING:Battery posts, terminals and related accessories
contain lead and lead compounds. Wash hands after
handling.
CAUTION: To prevent coil from burning, DO NOT apply voltage
to starter assembly for more than 10 seconds.

2004 Mitsubishi Endeavor Limited
2004 STARTING & CHARGING SYSTEMS Starters - Endeavor

1. Disconnect the field coil wire from "M" terminal of the magnetic switch. See
Fig. 4
.
2. Connect 12-volt battery between the "S" terminal and body.
3. Manually pull out the pinion as far as the pinion stopper position.
4. If the pinion remains out, everything is operating properly. If pinion moves in,
hold-in circuit is open. Replace the magnetic switch.
Fig. 4: Magnetic Switch Hold
-in Test

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
MAGNETIC SWITCH RETURN TEST
2004 Mitsubishi Endeavor Limited
2004 STARTING & CHARGING SYSTEMS Starters - Endeavor

Fig. 11: Exploded View of Starter

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
STARTER Disassembly (Snap & Stop Ring) 1. Press a lon
g socket wrench of a
ppropriate size to
the sto
p rin
g. Then ta
p the

2004 Mitsubishi Endeavor Limited
2004 STARTING & CHARGING SYSTEMS Starters - Endeavor

socket wrench to remove the stop ring to the pinion gear side. See Fig. 12
.
2. After removing the snap ring (by using snap-ring pliers), remove the stop ring
and the overrunning clutch. See Fig. 13
.
Fig. 12: Removing Stop Ring

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA

2004 Mitsubishi Endeavor Limited
2004 STARTING & CHARGING SYSTEMS Starters - Endeavor

Using a suitable pulling tool, pull the overrunning clutch stop ring over the snap
ring. See Fig. 14
.
Fig. 14: Installing Stop Ring & Snap Ring

Courtesy of MITSUBISHI MOTORS SALES OF AMERICA
STARTER SPECIFICATIONS STARTER SPECIFICATIONS Application
In. (mm)
Commutator RunoutStandard
.002" (0.5 mm)
Limit
.004" (.1 mm)
Commutator DiameterStandard
1.16" (29.4 mm)

2004 Mitsubishi Endeavor Limited
2004 STARTING & CHARGING SYSTEMS Starters - Endeavor

Fig. 34: Identifying Symptom Chart

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
SYMPTOM PROCEDURES INSPECTION PROCEDURE 1: When the Ignition Switch is Turned to the "ON" Position (Engine Stopped), the "TCL
OFF" Indicator Light does not Illuminate. INSPECTION PROCEDURE 2: When the Ignition Switch is Turned to the
"ON" Position (Engine Stopped), the TCL Work Indicator Light does not Illuminate. INSPECTION PROCEDURE 3:
The "TCL OFF" Indicator Li
ght Remains Illuminated After the En
gine is Started. INSPECTION PROCEDURE 4: The
TCL Work Indicator Light Remains Illuminated After the Engine is Started.

2004 Mitsubishi Endeavor LS
2004 BRAKES Traction Control System (TCL) - Endeavor