MITSUBISHI 380 2005 Workshop Manual

LOOSE PANEL
BODY42-84
DISASSEMBLY SERVICE POINT
.
<<A>> SUNROOF DEFLECTOR ASSEMBLY
REMOVAL
Slide the sunroof deflector assembly to the front of the vehicle
by holding the arrow area shown in the illustration with a
flat-tipped screwdriver, and remove it.
LOOSE PANEL
REMOVAL AND INSTALLATIONM1421003100056
REMOVAL
1. FRONT FLOOR BACKBONE BRACE

LOOSE PANEL
BODY42-85
COWL TOP COVER OUTER
REMOVAL STEPS
FRONT DECK GARNISH (REFER
TO GROUP 51, WINDSHIELD
WIPER P.51-17.)
2. COWL TOP COVER OUTER
UPPER FRAME TO FRONT PILLAR
BRACE REMOVAL STEPS
SPLASH SHIELD (REFER TO
P.42-10.)
3. UPPER FRAME TO FRONT PILLAR
BRACE
AIR GUIDE PANEL REMOVAL
STEPS
FRONT BUMPER ASSEMBLY
(REFER TO GROUP 51, FRONT
BUMPER P.51-2.)
4. AIR GUIDE PANEL CENTER
FRONT BUMPER
REINFORCEMENT ASSEMBLY
(REFER TO GROUP 51, FRONT
BUMPER P.51-2.)
5. AIR GUIDE PANEL SIDEFRONT BUMPER
REINFORCEMENT BRACKET
REMOVAL STEPS
FRONT BUMPER
REINFORCEMENT ASSEMBLY
(REFER TO GROUP 51, FRONT
BUMPER P.51-2.)
5. AIR GUIDE PANEL SIDE
6. FRONT BUMPER
REINFORCEMENT BRACKET
FRONT END STRUCTURE BAR
REMOVAL STEPS
RADIATOR GRILLE (REFER TO
GROUP 51, RADIATOR GRILLE
P.51-6.)
FRONT BUMPER MOUNTING
CLIPS UPPER (REFER TO GROUP
51, FRONT BUMPER P.51-2.)
HOOD DAMPER AND HOOD LATCH
(REFER TO P.42-8.)
7. COOLER TUBE ASSEMBLY
MOUNTING BOLT
8. FRONT END STRUCTURE BAR

SPECIFICATIONS
BODY42-86
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONSM1421005300216
ITEM SPECIFICATION
Hood
Hood hinge bolt (body side) 12
2 Nm (102 22 in-lb)
Hood hinge bolt (hood side) 12
2 Nm (102 22 in-lb)
Hood hinge nut (body side) 12
2 Nm (102 22 in-lb)
Hood latch bolt 9.0
2.0 Nm (80 17 in-lb)
Strut tower bar
Strut tower bar nut 12
2 Nm (102 22 in-lb)
Strut tower bar bracket nut 48
7 Nm (36 5 ft-lb)
Door
Door check bolt (body side) 9.0
2.0 Nm (80 17 in-lb)
Door check bolt (door side) 5.0
1.0 Nm (44 9 in-lb)
Door hinge bolt (body side) 27
5 Nm (20 4 ft-lb)
Door hinge bolt (door side) 21
4 Nm (16 2 ft-lb)
Door outside handle bolt 5.0
1.0 Nm (44 9 in-lb)
Door latch assembly screw 5.9
1.0 Nm (52 9 in-lb)
Door switch screw 3.9
1.0 Nm (35 8 in-lb)
Striker screw 24
3 Nm (18 2 ft-lb)
Trunk lid
Trunk lid hinge bolt (body side) 13
2 Nm ( 111 22 in-lb)
Trunk lid hinge bolt (trunk lid side) 13
2 Nm ( 111 22 in-lb)
Trunk lid hinge nut (trunk lid side) 13
2 Nm ( 111 22 in-lb)
Trunk lid latch bolt 9.0
2.0 Nm (80 17 in-lb)
Trunk lid striker bolt 5.0
1.0 Nm (44 9 in-lb)
Sunroof
Roof lid glass screw 4.0
0.5 Nm (36 4 in-lb)
Sunroof drip plate screw 2.0 N
m (18 in-lb)
Sunroof housing screw 2.0 N
m (18 in-lb)
Sunroof motor bolt 5.4 N
m (48 in-lb)
Loose panel
Cowl top cover outer bolt 11
2 Nm (98 17 in-lb)
Front end structure bar bolt 22
4 Nm (16 2 ft-lb)
12
2 Nm (102 22 in-lb)
11
2 Nm (98 17 in-lb)
Front floor backbone brace bolt 22
4 Nm (16 2 ft-lb)
Upper frame to front pillar brace bolt 22
4 Nm (16 2 ft-lb)

SPECIFICATIONS
BODY42-87
SERVICE SPECIFICATIONSM1421000300299
<DOOR>
<SUNROOF>
SEALANT AND ADHESIVESM1421000500204
<WINDOW GLASS>
<DOOR>
<TRUNK LID>ITEM STANDARD VALUE
Door inside handle knob play mm
(in)Front 26.1 - 58.1 (1.028 - 2.287) [Target
value 41 (1.61)]
Rear 30.3 - 58.1 (1.193 - 2.287) [Target
value 41 (1.61)]
Door inside handle lock knob stroke mm (in) 21.6 (0.850)
Door outside handle play mm (in) Front 10
3.5 (0.39 0.138)
Rear 11.2
4 (0.441 0.16)
Power window operation current A 5
1 [Power supply voltage 14.5
0.5V 25
C (77F)]
ITEM STANDARD VALUE
Roof lid glass operation current A 7 or less [at 20
C(68F)]
ITEM SPECIFIED ADHESIVE
Rear window glass 3 M
AAD part No. 8609 super fast urethane and 3 M AAD part No.
8608 super fast urethane primer or equivalent
Windshield
ITEM SPECIFIED SEALANT REMARK
Waterproof film 3 M
AAD Part No. 8633 or equivalent Ribbon sealer
ITEM SPECIFIED ADHESIVE TAPE
Front door opening outer
weatherstripAdhesive tape: Double-sided tape [7 mm (0.28 in) width, 85 mm (3.35
in) length and 0.8 mm (0.03 in) thickness]
Rear door opening outer
weatherstripAdhesive tape: Double-sided tape [7 mm (0.28 in) width, 50 mm (1.97
in) length and 0.8 mm (0.031 in) thickness]
ITEM SPECIFIED SEALANT REMARK
Trunk lid hinge 3 M
AAD part No. 8531 Heavy drip check sealer,
3 M
AAD part No. 8646 Automotive joint and
seam sealer or equivalentBody sealer

SPECIFICATIONS
BODY42-88
COMPONENT IDENTIFICATIONSM1421005400246
<DOOR CHECK>
<DOOR OPENING OUTER WEATHERSTRIP>APPLICABLE LOCATION IDENTIFICATION MARK
LH Front door P4FL
Rear door P4RL
RH Front door P4FR
Rear door P4RR
APPLICABLE SIDE IDENTIFICATION CLIP COLOR
LH Front door Pink
Rear door Yellow
RH Front door Turquoise
Rear door Blue

21A-1
GROUP 21A
CLUTCH
CONTENTS
GENERAL INFORMATION . . . . . . . .21A-2
SERVICE SPECIFICATIONS . . . . . . .21A-2
LUBRICANTS . . . . . . . . . . . . . . . . . .21A-2
ON-VEHICLE SERVICE . . . . . . . . . . .21A-2
CLUTCH PEDAL CHECK AND
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 21A-2
CLUTCH BLEEDING . . . . . . . . . . . . . . . . . 21A-3
CLUTCH PEDAL. . . . . . . . . . . . . . . . .21A-4
REMOVAL AND INSTALLATION . . . . . . . . 21A-4
CLUTCH CONTROL . . . . . . . . . . . . . .21A-5
REMOVAL AND INSTALLATION . . . . . . . . 21A-5
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 21A-6
DISASSEMBLY AND REASSEMBLY . . . . . 21A-7
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 21A-8

GENERAL INFORMATION
CLUTCH21A-2
GENERAL INFORMATION
M1211000100234
The clutch is a dry single-disc, diaphragm type;
hydraulic pressure is used for the clutch control. The
clutch shares a brake fluid reservoir with the brake
system.
SERVICE SPECIFICATIONS
M1211000300227
LUBRICANTS
M1211000400183
ON-VEHICLE SERVICE
CLUTCH PEDAL CHECK AND
ADJUSTMENT
M1211000900285
1. Turn up the carpet, etc. under the clutch pedal.2. Measure the clutch pedal height.
Standard value (A): 183
186 mm
3. Measure the clutch pedal clevis pin play.
Standard value (B): 1
3 mm Item Standard value
Clutch pedal height (mm)
183
186
Clutch pedal clevis pin play (mm) 1
3
Clutch pedal free play clearance (mm)
0.5
1.5
Distance between the clutch pedal and the clutch pedal
stopper when the clutch pedal is released (mm)35 or more
Item Specified lubricant Quantity
Clutch fluid Brake Fluid DOT 3 or DOT 4 As required
Pushrod assembly Rubber grease As required
Boot Rubber grease As required
Release cylinder push rod MITSUBISHI genuine grease Part
No.0101011As required

ON-VEHICLE SERVICE
CLUTCH21A-3
Do not push in the master cylinder pushrod at
this time, otherwise the clutch will not operate
properly.
4. If the clutch pedal height and clutch pedal clevis
pin play are not within the standard value, loosen
the setting nut to adjust the clutch pedal height
and clevis pin play to the standard value.
5. Check the clutch pedal switch clearance is within
specification when pedal height is adjusted
correctly and is positioned at rest. If adjustment is
required, loosen nut and rotate switch to achieve
correct clearance.
Switch clearance value (C): 0.5
1.5 mm
Nut tightening torque : 10 - 15 Nm6. After completing the adjustments, confirm that the
clutch pedal free play clearance (measured
between pedal switch and bracket) and the
distance between the clutch pedal (the face of the
pedal pad) and the clutch pedal stopper when the
clutch is disengaged are within the standard value
ranges.
Standard value (C): 0.5
1.5 mm
Standard value (D): 35 mm or more
7. If the clutch pedal free play and the distance
between the clutch pedal and the clutch pedal
stopper or toeboard when the clutch is
disengaged do not agree with the standard
values, it is probably the result of either air in the
hydraulic system or a faulty master cylinder,
release cylinder or clutch. Bleed the air, or
disassemble and inspect the master cylinder,
release cylinder or clutch.
CLUTCH BLEEDINGM1211001400205
Use the specified brake fluid. Do not mix brake
fluids.
Specified fluid: Brake fluid DOT 3 or DOT 4
1. Connect a hose with a bottle to the bleeder screw.
2. Open the bleed nipple.
3. Depress the clutch pedal slowly. Open the bleeder
screw to let air and brake fluid out. Close the
bleeder screw. Release the clutch pedal. Repeat
until only brake fluid and no air comes out.
4. Check that the brake fluid reservoir level stays
between &#34;MAX&#34; and &#34;MIN&#34; marks throughout the
clutch bleeding process.

CLUTCH PEDAL
CLUTCH21A-4
CLUTCH PEDAL
REMOVAL AND INSTALLATIONM1211001600232
Post-installation Operation
Clutch Pedal Adjustment (Refer to P.21A-2).
Removal steps
Instrument panel under cover
(Refer to GROUP 52A, Instrument
panel 52A-4).
1. Stopper
2. Snap pin
3. Clevis pin
4. Clutch master cylinder mounting
nut5. Clutch pedal assembly mounting
bolt
6. Pedal pad
7. Pedal stopper
8. Clutch pedal assembly
8. Clutch pedal switchRemoval steps (Continued)

CLUTCH CONTROL
CLUTCH21A-5
CLUTCH CONTROL
REMOVAL AND INSTALLATIONM1211001900255
Pre-removal Operation
Clutch Fluid DrainingPost-installation Operation
Clutch Fluid Supplying
Clutch Line Bleeding (Refer to P.21A-3).
Clutch Pedal Adjustment (Refer to P.21A-2).
Clutch master cylinder removal
steps
1. Reservoir hose and brake fluid
reservoir connection
2. Clutch damper
<<A>> >>A<<3. Clutch pipe assembly
Brake master cylinder assembly
and brake booster (Refer to
GROUP 35A, Master cylinder
assembly and brake booster
35A-26.)
4. Clevis pin5. Clutch master cylinder
6. Sealer
7. Reservoir hose
Clutch release cylinder removal
steps<<A>> >>A<<8.Clutch tube assembly
9.Clutch release cylinder
Clutch line removal steps
<<A>> >>A<<10.Clutch hose bracket
<<A>> >>A<<11. Clutch hoseClutch master cylinder removal
steps (Continued)