2004-2007 Mitsubishi Endeavor Service & Repair Manual
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MITSUBISHI
Endeavor
BRAKES 9-10
ANTI-LOCK BRAKE
SYSTEM (ABS) 9-10
General Information 9-10
Wheel Speed Sensor Rings
(Toothed Rings) 9-11
Removal & Installation 9-11
Wheel Speed Sensors 9-11
Removal & Installation 9-11
BLEEDING THE BRAKE
SYSTEM 9-12
Bleeding Procedure 9-12
FRONT DISC BRAKES 9-12
Brake Caliper 9-12
Removal & Installation 9-12
Disc Brake Pads 9-13
Removal & Installation 9-13
PARKING BRAKE 9-15
Parking Brake Cables 9-15
Adjustment 9-15
Parking Brake Shoes 9-16
Adjustment 9-17
Removal & Installation 9-16
REAR DISC BRAKES 9-14
Brake Caliper 9-14
Removal & Installation 9-14
Disc Brake Pads 9-14
Removal & Installation 9-14
CHASSIS ELECTRICAL 9-17
AIR BAG (SUPPLEMENTAL
RESTRAINT SYSTEM) 9-17
Air Bag Module 9-18
Removal & Installation 9-18
General Information 9-17
Arming the System 9-18
Clockspring Centering 9-18
Disarming the System 9-18
Service Precautions 9-17
DRIVETRAIN.
Automatic Transaxle Assembly...9-19
Removal & Installation 9-19
Front Halfshaft 9-21
CV-boot Inspection 9-21
Removal & Installation 9-21
Rear Differential Carrier
Assembly 9-22
Removal & Installation 9-22
Rear Driveshaft 9-23
Removal & Installation 9-23
Rear Halfshaft 9-23
Removal & Installation 9-23
Rear Pinion Seal 9-24
Removal & Installation 9-24
Transfer Case Assembly 9-21
Removal & Installation 9-21
ENGINE COOLING 9-25
Engine Fan 9-25
Removal & Installation 9-25
Radiator 9-25
Removal & Installation 9-25
Thermostat 9-26
Removal & Installation 9-26
Water Pump 9-27
Removal & Installation 9-27
ENGINE ELECTRICAL 9-28
CHARGING SYSTEM 9-28
Alternator 9-28
Removal & Installation 9-28
IGNITION SYSTEM 9-28
Ignition Coil 9-28
Removal & Installation 9-28
Ignition Timing 9-29
Adjustment 9-29
Inspection 9-29
SparkPlugs 9-29
Removal & Installation 9-29
STARTING SYSTEM 9-30
Starter 9-30
Removal & Installation 9-30
Solenoid or Relay
Replacement 9-30
ENGINE MECHANICAL 9-30
Accessory Drive Belts 9-30
Accessory Belt Routing 9-30
Adjustment 9-30
Inspection 9-30
Removal & Installation 9-32
Camshaft and Valve Lifters 9-32
Inspection 9-32
Removal & Installation 9-32
Crankshaft Damper 9-34
Removal & Installation 9-34
Crankshaft Front Seal 9-34
Removal & Installation 9-34
Cylinder Head 9-35
Removal & Installation 9-35
Engine Assembly 9-35
Removal & Installation 9-35
Exhaust Manifold 9-37
Removal & Installation 9-37
Flexplate 9-39
Removal & Installation 9-39
Intake Manifold 9-40
Removal & Installation 9-40
Main Bearing Torque
Sequence 9-44
Oil Pan 9-42
Removal & Installation 9-42
Oil Pump 9-43
Inspection 9-43
Removal & Installation 9-43
Piston and Ring 9-44
Positioning 9-44
Rear Main Seal 9-44
Removal & Installation 9-44
Rocker Arms/Shafts 9-45
Removal & Installation 9-45
Timing Belt and Sprockets 9-46
Removal & Installation 9-46
Timing Belt Front Cover 9-45
Removal & Installation 9-45
Valve Covers 9-47
Removal & Installation 9-47
Valve Lash 9-47
Adjustment 9-47
ENGINE PERFORMANCE &
EMISSION CONTROL 9-49
Accelerator Pedal Position
(APP) Sensor 9-49
Location 9-49
Operation 9-49
Removal & Installation 9-49
Testing 9-49
QO MITSUBISHI
ENDEAVOR
Barometric Pressure (BARO)
Sensor 9-49
Location 9-49
Operation 9-49
Removal & Installation 9-49
Testing 9-49
Camshaft Position (CMP)
Sensor 9-50
LocafJon 9-50
Operation 9-50
Removal & Installation 9-50
Testing 9-50
Component Locations 9-49
Crankshaft Position (CKP)
Sensor 9-50
Location 9-50
Operation 9-51
Removal & Installation 9-51
Testing 9-51
Electric Fan Switch 9-51
Location 9-51
Operation 9-51
Removal & Installation 9-51
Testing 9-52
Engine Coolant Temperature
(ECT) Sensor 9-52
Location 9-52
Operation 9-52
Removal & Installation 9-52
Testing 9-52
Fuel Level Sending Unit 9-53
Location 9-53
Operation 9-53
Removal & Installation 9-53
Testing 9-53
Heated Oxygen (H02S) Sensor...9-54
Location 9-54
Operation 9-54
Removal & Installation 9-54
Testing 9-54
Intake Air Temperature
(IAT) Sensor 9-55
Location 9-55
Operation 9-55
Removal & Installation 9-55
Testing 9-55
Knock Sensor (KS) 9-55
Location 9-55
Operation 9-55
Removal & Installation 9-55
Testing 9-55
Malfunction Indicator
Light (MIL) 9-56
Reset Procedures 9-56
Manifold Absolute Pressure
(MAP) Sensor 9-56
Location... ....9-56
Operatio
Remova
Testing.
Mass Air F
Sensor...
Location
Operatio
Removal
Testing.
Oil Pressur
Location
Operatio
Testing.
Powertrain
Module (P
Location
Operatio
Removal
Testing.
Throttle Po
Sensor(Tf
Location
Operatior
Removal
Testing..
Vehicle Spe
Location
Operation
Removal
Testing..
9-56
& Installation 9-56
9.55
w(MAF)
9-56
9-56
9-56
& Installation 9-56
9-56
Sensor 9-56
9-56
9-56
9-57
ontrol
}M) 9-57
9-57
9-57
i Installation 9-57
9-57
ion
)) 9-57
9-57
9-57
i Installation 9-57
9-58
d Sensor (VSS) 9-58
9-58
9-58
Installation 9-58
....9-58
FUEL SYSTEM 9-59
GASOLINE FL
INJECTION i
Fuel Filter...
Removal
Fuel Pump..
Removal
Fuel Rail & I
Removal
Fuel System
Precaution:
Fuel Tank....
Removal
Idle Speed..
Adjustmer
Relieving Fu
Pressure...
Throttle Bod\l
EL
YSTEM 9-59
9-59
Installation 9-59
9-59
Installation 9-59
jectors 9-61
Installation 9-61
ervice
9-59
9-60
Installation 9-60
9-62
9-62
System
9-59
9-62
Installation 9-62
HEATING & />IR
CONDITIONING SYSTEM ....9-63
Blower Motor
Removal &
9-63
Installation 9-63
Heater Core 9-64
Removal & Installation 9-64
PRECAUTIONS 9-10
SPECIFICATIONS AND
MAINTENANCE CHARTS 9-4
Brake Specifications 9-8
Camshaft Specifications 9-6
Capacities 9-5
Crankshaft and Connecting
Rod Specifications 9-6
Engine and Vehicle
Identification 9-4
Engine Tune-Up
Specifications 9-4
Fluid Specifications 9-5
General Engine
Specifications 9-4
Piston and Ring
Specifications 9-6
Scheduled Maintenance
Intervals 9-8
Tire, Wheel and Ball Joint
Specifications 9-7
Torque Specifications 9-5
Valve Specifications 9-7
Wheel Alignment 9-7
STEERING 9-66
Power Rack & Pinion
Steering Gear 9-66
Removal & Installation 9-66
Power Steering Pump 9-67
Bleeding 9-68
Removal & Installation 9-67
Steering Linkage 9-69
Removal & Installation 9-69
SUSPENSION 9-69
FRONT SUSPENSION 9-69
Lower Ball Joint 9-69
Removal & Installation 9-69
Lower Control Arm 9-69
Control ARM Bushing
Replacement 9-69
Removal & Installation 9-69
MacPherson Strut 9-70
Overhaul 9-71
Removal & Installation 9-70
Stabilizer Bar 9-71
Removal & Installation 9-71
Steering Knuckle 9-72
Removal & Installation 9-72
MITSUBISHI
ENDEAVOR
9-3
Wheel Hub and Bearing 9-73
Adjustment 9-73
Removal & Installation 9-73
REAR SUSPENSION 9-74
Coil Spring 9-74
Removal & Installation 9-74
Control Arms/Links 9-74
Removal & Installation 9-74
Shock Absorber 9-76
Removal & Installation 9-76
Testing 9-76
Stabilizer Bar 9-77
Removal & Installation 9-77
Wheel Hub and Bearing 9-78
Adjustment 9-78
Removal & Installation 9-78
9-4
MITSUBISHI
ENDEAVOR
SPECIFICATIONS AND MAINTENANCE CHARTS
ENGINE AND VEHICLE IDENTIFICATION CHART
Engine Model Year
Code Liters (cc) Cu. In. Cyl. Fuel Sys. Engine Type Eng. Mfg. Code Year
3.8 (3828) 233.6 MFI
MFI Multi-port Fuel Injection
Mitsubishi 2007
2008
GENERAL ENCilNE SPECIFICATIONS
Engine Net
Displacement Engine Horsepower
Year Liters ID/VIN @ rpm
Net
Torque @ rpm
(ft. Ibs.)
Bore x Stroke
(in.)
Com-
pression
Ratio
Oil
Pressure
~ rpm
2007
2008
3.8
3.8
6G75/S
6G75/S
225@5000
225@5000
255@3750
255@3750
3.74x3.54
3.74x3.54
10.0:1
10.0:1
©
©
© 4.2 or more psi @ idle
43-100 @ 3500 rpm
22140JNDE_C0002
ENGINE TUNE4JP SPECIFICATIONS
Year
2007
2008
Engine
Displacement
Liters
3.8
3.8
Engine
IDA/IN
6G75/S
6G75/S
Spark Plugs
Gap
(in.)
0.028-0.031
0.028-0.031
Ignition
Timing
(deg.)
MT AT
—
®
ii :
Fuel
Pump
(psi)
47
47
Idle
Speed
(rpm)
MT AT
—
—
:2i
2
Valve
Clearance
In.
HYD
HYD
Ex.
HYD
HYD
HYD: Hydraulic
JJ Base ignition timing: 2-8 degrees BTDC
Actual ignition timing: 10 degrees BTDC
@ 580-780 rpm's
22140.ENDE C0003
MITSUBISHI
ENDEAVOR
9-5
CAPACITIES
Engine
Displacement
Year Model Liters
2007 Endeavor 3.8
2008 Endeavor 3.8
Engine
IDA/IN
6G75/S
6G75/S
Engine
Oil with
Filter
(qts.)
4.5
4.5
Transmission Transfer
(pts.) Case
5-Spd
—
—
Auto. (pts.)
•1) 1.12
® 1.12
Drive
Axle
Front Rear
(pts.) (pts.)
— 2.4
— 2.4
Fuel
Tank
(gai.)
21 4
21.4
Cooling
System
(qts.)
2
2
'1 ' FWD: 17.8 pts.
AWD 18.6 pts.
(2) FWD & AWD without tow kit: 95 qts
AWD with tow kit: 10.1 qts.
1 : '.
FLUID SPECIFICATIONS
Engine
Displ. Engine Man. Auto.
Year Model Liters (VIN) Oil Trans. Trans.
2007
2008
Endeavor
Endeavor
6G75/S
6G75/S
5W-20
5W-20
—
—
ATF SPIN
ATF SPIN
Drive Axle
Front Rear
—
—
80W-90
80W-90
Power Brake
Transfei Steering Master Cooling
Case Fluid Cylinder System
SAE90
SAE90
Mitsubishi
Mitsubishi
DOT 3-4
DOT 3-4
Long Life
Long Life
• •. •.
VALVE SPECIFICATIONS
Spring
Engine Seat Face Spring Test Installed
Displacement Engine Angle Angle Pressure Height
Year Liters IDA/IN (deg.) (deg.) (Ibs. @ in.) (in.)
2007
2008
3.8
3.8
6G75/S
6G75/S
NS
NS
43.5-44
43.5-44
60@1.74
60@1.74
1.740
1.740
Stem-to-Guide Stem
Clearance Diameter
(in.) (in.)
Intake Exhaust Intake Exhaust
0.0008-
0.0019
0.0008-
0.0019
0.0016-
0.0023
0.0014-
0.0024
0.240
0.240
0.240
0.240
NS - Not specified by manufacturer
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Full Search Facility
Print one or all pages of your manual
$32.99
$42.99
You are purchasing a comprehensive 2004-2007 Mitsubishi Endeavor Factory Service Workshop Manual. This manual is utilized by professional technicians at Mitsubishi dealerships to service and repair vehicles. It encompasses a wide range of services and repairs, from basic oil changes to intricate transmission rebuilds, making it an invaluable resource for both professional mechanics and DIY enthusiasts.
The manual covers an extensive list of sections including Antilock brakes, Bumpers, Doors, Keyless Entry, Lightning system, Disk brakes, Park Brake, Hydraulic Brake, Front suspension, Rear Suspension, Interior Trim, Exterior trim, HVAC, Engine Cooling, Engine Exhaust, Engine Electrical, Engine, Power Steering, Roof and Sunroof, SIR, Steering wheel, Transmission, Wheel drive shaft, and Washer and wiper.
It is available in a .PDF format and is compatible with Win95/98/ME/XP/Vista/7, Linux, and MAC operating systems. The manual is suitable for the 2004, 2005, 2006, and 2007 model years of the Mitsubishi Endeavor.
