2004-2010 Mitsubishi Endeavor Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Endeavor Production Years Covered: 2004, 2005, 2006, 2007, 2008, 2009, 2010 Codes Platform: Mitsubishi PS platform (shared with Mitsubishi Outlander and Lancer) 👋 Introduction Market Position Segment: Mid-size Crossover SUV Key Selling Points: Spacious interior, available All-Wheel Drive (AWD), comfortable ride, distinctive styling. Competitive Analysis Key Competitors: Ford Edge, Toyota Highlander, Honda Pilot, Chevrolet Equinox, Nissan Murano, Hyundai Santa Fe. Key Features Design Philosophy: A blend of American market sensibilities with Mitsubishi's engineering heritage. Interior Versatility: Flexible seating arrangements and ample cargo space for family use. 📋 Manual Details Coverage Areas Covered Model Years: 2004-2010 Regions Covered: North America (primary focus, though general principles apply globally) Page Count Estimated Page Count: Extensive (typically thousands of pages for a complete factory-level manual, though this is a digital compilation) Manual Type Type: Workshop Service Repair Manual (WSRM) / Factory Service Manual (FSM) Language Language: English Format File Format: PDF Delivery Method: Instant Download Requirements Software Requirements: Adobe PDF Reader, WinZip (for extraction if compressed) Compatibility: All Versions of Windows & Mac 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, block, pistons, crankshaft, camshafts, timing system, lubrication system, cooling system, intake and exhaust manifolds. Engine Performance: Fuel injection system, ignition system, emission control systems, engine management (ECM/PCM), sensors and actuators. Transmission Manual: Manual transmission operation, disassembly, assembly, clutch system, torque converter (if applicable), transmission control module. Transmission Automatic: Automatic transmission operation, internal components, valve body, torque converter, transmission control module, fluid and filter replacement. Drivetrain: Front-wheel drive (FWD) and All-wheel drive (AWD) systems, differentials, drive shafts, CV joints, rear axle. Brakes: Brake system components (master cylinder, calipers, rotors, pads), hydraulic system, parking brake, Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD). Suspension: Front and rear suspension components (struts, shocks, control arms, ball joints, bushings), steering system, power steering. Steering: Steering column, steering gear, power steering pump, hydraulic lines, steering linkage. Electrical System: Battery, charging system (alternator), starting system (starter motor), lighting systems (headlights, taillights, interior), horn, fuses, relays. Body And Frame: Body panels, doors, hood, trunk, bumpers, chassis, structural components, corrosion protection. HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system components, refrigerant, compressor, condenser, evaporator, blower motor, climate controls. Interior: Seats, dashboard, trim panels, airbags, seat belts, interior lighting, audio systems, power accessories (windows, locks). Safety Systems: Airbag system components and diagnosis, seat belt pre-tensioners. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement. Diagnostics: Troubleshooting guides, diagnostic trouble codes (DTCs), symptom-based diagnosis, component testing procedures. Repair: Step-by-step repair instructions for all major systems, component removal and installation, adjustments. Overhaul: Engine and transmission overhaul procedures, rebuilding procedures for major components. Wiring Schematics: Comprehensive wiring diagrams for all electrical systems, component locations, connector pinouts. Specifications Tables: Torque specifications, clearances, tolerances, fluid capacities, electrical specifications. Technical Depth Depth: Comprehensive (covers everything from basic maintenance to advanced diagnostics and complete rebuilds). Target Audience: Do-it-yourselfers (DIY) and professional mechanics. 📊 Manual Specifications File Format Quality: High-resolution, digitally rendered. Print Quality Feature: Fully Printable Zoom Capability: YES (Zoom IN/OUT) Binding Type Type: Digital (No physical binding, printable pages) Paper Type Type: Not applicable (Digital format) ⚙️ Engine Specifications Primary Engine Engine Code: 6G75 Engine Type: 3.8L V6 SOHC (Single Overhead Camshaft), later MIVEC (Mitsubishi Innovative Valve timing Electronic Control) on some models. Displacement: 3828 cc (3.8 Liters) Performance Horsepower Early Models: 215 hp @ 5000 rpm Torque Early Models: 245 lb-ft @ 3750 rpm Horsepower Late Models Mivec: 235 hp @ 6000 rpm Torque Late Models Mivec: 254 lb-ft @ 3750 rpm Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) / Sequential Electronic Fuel Injection (SEFI). Fuel Type: Unleaded gasoline (87 octane recommended, higher may improve performance). 🔧 Transmission Standard Type: 6-speed INVECS-II Sport Mode Automatic Transmission with manual shift control. Optional Type: None offered on the Endeavor, always automatic transmission. Features Drive Modes: Typically features a 'Sport Mode' for more aggressive shifting patterns. Fluid Type Fluid Specification: DIAMOND ATF SP-III (refer to manual for exact specifications and change intervals). 📐 Dimensions Exterior Length: Approximately 191.7 inches (4870 mm) Width: Approximately 75.4 inches (1915 mm) Height: Approximately 67.1 inches (1705 mm) Wheelbase: Approximately 107.0 inches (2718 mm) Cargo Cargo Volume Behind Second Row: Approximately 40.0 cubic feet (1133 liters) Cargo Volume With Second Row Folded: Approximately 77.0 cubic feet (2180 liters) Weights Curb Weight FWD: Approximately 4,321 lbs (1960 kg) Curb Weight AWD: Approximately 4,475 lbs (2030 kg) Towing Capacity: 3,500 lbs (1588 kg) standard, up to 5,000 lbs (2268 kg) with optional towing package. 🛡️ Safety Features Ratings NHTSA Frontal Crash Test: 5-star rating (driver and passenger) for the 2004-2006 models. NHTSA Side Impact Crash Test: 5-star rating (front and rear passengers) for the 2004-2006 models. IIHS Crash Test Front: Good (G) rating. Active Features ABS:...
Unleaded gasoline (87 octane recommended, higher may improve performance).
🔧 Transmission
Standard
Type:
6-speed INVECS-II Sport Mode Automatic Transmission with manual shift control.
Optional
Type:
None offered on the Endeavor, always automatic transmission.
Features
Drive Modes:
Typically features a 'Sport Mode' for more aggressive shifting patterns.
Fluid Type
Fluid Specification:
DIAMOND ATF SP-III (refer to manual for exact specifications and change intervals).
📐 Dimensions
Exterior
Length:
Approximately 191.7 inches (4870 mm)
Width:
Approximately 75.4 inches (1915 mm)
Height:
Approximately 67.1 inches (1705 mm)
Wheelbase:
Approximately 107.0 inches (2718 mm)
Cargo
Cargo Volume Behind Second Row:
Approximately 40.0 cubic feet (1133 liters)
Cargo Volume With Second Row Folded:
Approximately 77.0 cubic feet (2180 liters)
Weights
Curb Weight FWD:
Approximately 4,321 lbs (1960 kg)
Curb Weight AWD:
Approximately 4,475 lbs (2030 kg)
Towing Capacity:
3,500 lbs (1588 kg) standard, up to 5,000 lbs (2268 kg) with optional towing package.
🛡️ Safety Features
Ratings
NHTSA Frontal Crash Test:
5-star rating (driver and passenger) for the 2004-2006 models.
NHTSA Side Impact Crash Test:
5-star rating (front and rear passengers) for the 2004-2006 models.
IIHS Crash Test Front:
Good (G) rating.
Active Features
ABS:
Standard Anti-lock Braking System (ABS).
Ebd:
Standard Electronic Brake-force Distribution (EBD).
Traction Control:
Standard Traction Control System (TCS).
Stability Control:
Standard Electronic Stability Control (ESC) often referred to as Active Stability Control (ASC) by Mitsubishi.
Passive Features
Airbags:
Frontal airbags for driver and front passenger, available side-impact airbags, available side curtain airbags.
Seat Belts:
3-point seat belts with pretensioners and load limiters for front seats, LATCH child seat anchors.
💡 Technology Features
Infotainment
Audio System:
Standard AM/FM/CD audio system with 6 speakers. Available Rockford Fosgate premium audio system with subwoofer.
Navigation:
Optional factory-installed navigation system available on higher trims.
Driver Assistance
Parking Assistance:
Rear parking sensors (available on some trims).
Connectivity
Auxiliary Input:
Available auxiliary audio input jack for connecting external music players.
Power Outlets:
12V accessory power outlets in the cabin.
🔧 Maintenance
Service Intervals
Oil Change:
Every 7,500 miles (12,000 km) or 6 months, whichever comes first (using synthetic blend or full synthetic oil).
Engine Air Filter:
Inspect every 7,500 miles, replace as needed (typically every 15,000-30,000 miles).
Cabin Air Filter:
Inspect every 7,500 miles, replace as needed (typically every 15,000 miles or annually).
Spark Plugs:
Typically iridium-tipped spark plugs, recommended replacement every 100,000 miles.
Transmission Fluid Change:
Refer to manual, but generally recommended around 30,000-60,000 miles for optimal performance, especially under severe driving conditions. Use DIAMOND ATF SP-III.
Fluid Specifications
Engine Oil:
SAE 5W-30 (API Service SG, SH, SJ, SL, SM, SN or ILSAC GF-3, GF-4, GF-5 recommended).
Coolant:
Mitsubishi DiaQueen Super Long Life Coolant (SLLC) or equivalent ethylene glycol-based coolant with silicate inhibitors, 50/50 mix with distilled water.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Power Steering Fluid:
Power Steering Fluid (refer to manual for specific type).
Known Issues
Common Issue 1:
Premature wear of front suspension components (ball joints, control arm bushings) due to vehicle weight and typical usage.
Common Issue 2:
Occasional issues with the ABS/TCS/ESC system sensors or control modules, often indicated by warning lights.
Common Issue 3:
Potential for catalytic converter failure or exhaust system leaks.
Common Issue 4:
Automatic transmission shifting issues or solenoid failures in some cases, regular fluid maintenance is crucial.
📚 Vehicle History
Brand Heritage
Manufacturer:
Mitsubishi Motors Corporation, a Japanese multinational automotive manufacturer.
Model Evolution
First Generation Introduction:
The Mitsubishi Endeavor was introduced for the 2004 model year as an all-new model.
Mid-Cycle Refresh:
Received a significant refresh for the 2007 model year, featuring updated styling, interior refinements, and the introduction of the MIVEC variable valve timing system on the V6 engine.
Production
Manufacturing Location:
Normal, Illinois, USA (North American production facility).
End Of Production:
Production ceased after the 2011 model year, with no direct successor in the North American market.
🏆 Awards & Recognition
Recognitions
Recognition 1:
J.D. Power and Associates Initial Quality Study (IQS) ratings often placed it competitively within its segment.
Recognition 2:
Earned a 5-star safety rating from the National Highway Traffic Safety Administration (NHTSA) for frontal and side impact tests in early model years.
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