2004 MITSUBISHI ENDEAVOR oil

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

2. Connect a 12-volt battery between "S" terminal and "M" terminal.
3. If the pinion moves out, the pull-in coil is good. If it doesn't, replace the
magnetic switch.
Fig. 3: Magnetic Switch Pull
-in Test

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
MAGNETIC SWITCH HOLD IN TEST
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

1. Disconnect the field coil wire from the "M" terminal of the magnetic switch.
SeeFig. 5
.
2. Connect a 12-volt battery between the "M" terminal and body.
3. Pull the pinion out and release. If the pinion quickly returns to its original
position, everything is operating properly. If it doesn't, replace the magnetic
switch. WARNING:Be careful not to get your fingers caught when
pulling out the pinion.
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

Fig. 7: Checking Overrunning Clutc
h
Courtesy of KIA MOTORS AMERICA, INC.
FRONT & REAR BRACKET BUSHING CHECK Inspect the bushing for wear or burrs. If the bushing is worn or burred, replace the
front bracket assembly or rear bracket assembly. ARMATURE CHECK 1. Check that the armature coil is not grounded.
2. Place armature in a growler. See Fig. 8
.
3. Hold a thin steel blade parallel and just above while rotating the armature
slowly in the growler. A shorted armature will cause a blade to vibrate and
attract to the core. Replace the shorted armature.
4. Check the insulation between the armature coil cores and the commutator
segments. They are normal if there is no continuity. See Fig. 9
.
5. Check for continuity between the segments. The condition is normal if there is
continuit
y. See Fig. 10
.

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

Fig. 9: Checking Armature Coil Ground Test

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

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

Fig. 10: Checking Armature Coil Open Circuit

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
REMOVAL & INSTALLATION
OVERHAUL NOTE: Information is not available from manufacturer.
NOTE: To assist in overhaul use illustration. See Fig. 11
.

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

Fig. 13: Removing Snap Ring

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA
Cleaning Overrunning clutch is pre-lubricated at the factory and solvent will wash lubrication
from clutch. The drive unit may be cleaned with a brush moistened with cleaning
solvent and wiped dry with a cloth. Reassembl
y (Sna
p & Sto
p Rin
g)
CAUTION: Do not immerse drive unit and parts in cleaning
solvent. Immersing the yoke and field coil assembly
and/or armature will damage insulation. Wipe these
parts with a cloth only.

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