engine MITSUBISHI 380 2005 Workshop Manual

BASIC BRAKE SYSTEM DIAGNOSIS
BASIC BRAKE SYSTEM35A-5
STEP 4. Check for pinched or restricted brake
tube or hose.
Q: Is there a pinched or restricted brake tube or hose?
YES :
Replace that complete section of brake tube
or brake hose. Then go to Step 7.
NO : Go to Step 5.
STEP 5. Check for oil, water, etc., on the pad
contact surfaces of all brakes.
Q: Is oil, water, etc., on the pad contact surface?
YES :
Replace the part and determine the
source/cause of foreign material. Recheck
symptom. Then go to Step 7.
NO : The procedure is complete. If condition
persists for vehicles without ABS, go to Step
6.
STEP 7. Recheck symptom.
Q: Is the symptom eliminated?
YES :
The procedure is complete.
NO : Start over at step 1. If a new symptom
surfaces, refer to the appropriate symptom
chart.
INSPECTION PROCEDURE 3: Increased Pedal Stroke (Reduced Pedal-to-Floor Board Clearance)
.
DIAGNOSIS
STEP 1. Check for spongy (not firm) brakes.
(1) With engine not running, depress the brake pedal
rapidly several times to deplete booster vacuum
reserve.
(2) With the brake pedal fully released, depress the
brake pedal slowly until it stops.
(3) With a measuring device (ruler, etc.) next to the
brake pedal, depress the pedal firmly and
measure the distance the pedal traveled.
Q: Is the distance greater than 20 mm (0.8 inch)?
YES :
Bleed the brakes to remove air in the fluid
(Refer to P.35A-16). Then go to Step 7.
NO : Go to Step 2.
STEP 2. Check the pad for wear.
Refer to P.35A-17.
Q: Is the pad thickness outside of specifications?
YES :
Replace the part. Then go to Step 7.
NO : Go to Step 3.
STEP 3. Check the vacuum hose and check valve
for damage.
Refer to P.35A-15.
Q: Is there a damage?
YES :
Replace the part. Then go to Step 7.
NO : Go to Step 4.
STEP 4. Check the master cylinder function.
Refer to P.35A-23.
Q: Is there a fault?
YES :
Repair it. Then go to Step 7.
NO : Go to Step 5.
STEP 5. Check for brake fluid leaks.
Q: Is there a leak?
YES :
Check the connection for looseness,
corrosion, etc. Clean and repair as
necessary. If leaking in any tube or hose
section, replace the complete tube or hose.
Then go to Step 7 .
NO : Go to Step 6.
STEP 6. Check for excessive clearance between
the push rod and primary piston.
Refer to P.35A-26.
Q: Is the clearance outside of specifications?
YES :
Adjust the clearance. Then go to Step 7.
NO : Go to Step 7.
STEP 7. Recheck symptom.
Q: Is the symptom eliminated?
YES :
The procedure is complete.
NO : Start over at step 1. If a new symptom
surfaces, refer to the symptom chart.

ON-VEHICLE SERVICE
BASIC BRAKE SYSTEM35A-14
BRAKE PEDAL FREE PLAY
1. Turn the ignition switch to the "LOCK" (OFF) position, and
depress the brake pedal two or three times. After eliminating
the vacuum in the brake booster, press the pedal down by
hand, and confirm that the amount of movement before
resistance is met (free play) is within the standard value
range.
Standard value: 3
8 mm (0.12 0.31 inch)
2. If the brake pedal play is not within the standard value,
check the following, and adjust or replace if necessary:
Excessive play between the brake pedal and the clevis pin,
or between the clevis pin and the brake booster operating
rod
Brake pedal height
Installation position of the stop light switch, etc.
CLEARANCE BETWEEN BRAKE PEDAL AND
DASH PANEL
1. Turn up the carpet, etc. under the brake pedal.
2. Start the engine, depress the brake pedal with
approximately 500 N (112 pounds) of force, and measure
the clearance between the brake pedal and the dash panel.
Standard value: 110 mm (4.33 inches) or more [From
the surface of dash panel to the face of pedal pad]
3. If the clearance is outside the standard value, check for air
trapped in the brake line and check the thickness of the disc
brake pad. Andjust and replace defective parts as required.
4. Return the carpet etc. to its original position.
BRAKE BOOSTER OPERATING TESTM1351001000372
1. For simple checking of the brake booster operation, carry
out the following tests:
(1) Run the engine for one or two minutes, and then stop it. If
the pedal depresses fully the first time but gradually
becomes higher when depressed succeeding times, the
booster is operating properly. If the pedal height remains
unchanged, the booster is defective. Go to step 2.

ON-VEHICLE SERVICE
BASIC BRAKE SYSTEM35A-15
(2) With the engine stopped, step on the brake pedal several
times. Then step on the brake pedal and start the engine.
If the pedal moves downward slightly, the booster is in
good condition. If there is no change, the booster is
defective. Go to step 3.
(3) With the engine running, step on the brake pedal and
then stop the engine. Hold the pedal depressed for 30
seconds. If the pedal height does not change, the booster
is in good condition, if the pedal rises, the booster is
defective.
2. If the above three tests are okay, the booster is OK. If one of
the above three tests is not okay, the check valve, vacuum
hose, or booster is defective. Check the check valve (Refer
to P.35A-15), vacuum hose for leaks, high volume engine
vacuum applied to booster. Repair or replace as necessary.
If these are OK, replace booster and repeat this test starting
at Step 1.
CHECK VALVE OPERATION CHECKM1351009000376
The check valve should not be removed from the vacuum
hose.
1. Remove the vacuum hose. (Refer to P.35A-26).
If the check valve is defective, replace it as an assembly
together with the vacuum hose.
2. Check the operation of the check valve by using a vacuum
pump.
VACUUM PUMP
CONNECTIONCRITERIA
Connection at the brake
booster side (A)A negative pressure
(vacuum) is created and
held.
Connection at the intake
manifold side (B)A negative pressure
(vacuum) is not created.

ON-VEHICLE SERVICE
BASIC BRAKE SYSTEM35A-16
BLEEDINGM1351001400455
Use only brake fluid DOT 3 or DOT 4. Never mix the speci-
fied brake fluid with other fluid as it will influence the brak-
ing performance significantly.
.
MASTER CYLINDER BLEEDING
The master cylinder used has no check valve, so if bleeding is
carried out by the following procedure, bleeding of air from the
brake pipeline will become easier. (When brake fluid is not con-
tained in the master cylinder).
1. Fill the reserve tank with brake fluid.
2. Keep the brake pedal depressed.
3. Have another person cover the master cylinder outlet with a
finger.
4. With the outlet still closed, release the brake pedal.
5. Repeat steps 2
4 three or four times to fill the inside of the
master cylinder with brake fluid.
.
BRAKE LINE BLEEDING
Start the engine and bleed the air in the sequence shown in the
figure.

DISC BRAKE ASSEMBLY
BASIC BRAKE SYSTEM35A-31
INSTALLATION SERVICE POINT
.
>>A<< BRAKE DRAG FORCE CHECK
1. In order to measure the brake drag force, measure the hub
torque with the pads removed by the following procedure.
Use a spring scale to measure the hub torque in the forward
direction. Record hub torque with pads removed.
Do not let any oil, grease or other contamination get onto
the friction surfaces of the pads and brake discs.
2. After re-installing the caliper support to the knuckle, install
the pad clips and the pads to the caliper support.
3. Clean the piston and insert into cylinder with special tool
MB990520.
4. Be careful that the piston boot does not become caught,
when lowering the caliper assembly and installing the lock
pin bolt.
5. Check the brake drag force as follows.
(1) Start the engine and hold the brake pedal down for 5
seconds. [Pedal depression force: approximately 200 N
(45 pound)]
(2) Stop the engine.
(3) Turn the brake disc forward 10 times.

DISC BRAKE ASSEMBLY
BASIC BRAKE SYSTEM35A-32
(4) Use a spring scale to measure the hub torque with pads
installed in the same direction as earlier.
(5) Calculate the drag force of the disc brake [difference
between hub torque with pads installed and hub torque
with pads removed].
Standard value:
<Front
3.8L engine> 64 N (14 pounds) or less
<Rear> 54 N (12 pounds) or less
6. If the brake drag force exceeds the standard value,
disassemble and clean the piston. Check for corrosion or
worn piston seal, and check the sliding condition of the lock
pin and guide pin.
INSPECTIONM1351008100046.
BRAKE DISC CHECK
Disc wear (Refer to P.35A-19).
Disc run-out (Refer to P.35A-19).

00-1
GROUP 00
GENERAL
CONTENTS
HOW TO USE THIS MANUAL . . . . . .00-3
TROUBLESHOOTING GUIDELINES00-6
HOW TO USE TROUBLESHOOTING /
INSPECTION SERVICE POINTS. . . .00-7
TROUBLESHOOTING CONTENTS . . . . . . 00-7
HOW TO USE THE INSPECTION
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . 00-9
CONNECTOR MEASUREMENT SERVICE
POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-11
CONNECTOR INSPECTION SERVICE
POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-13
HOW TO COPE WITH INTERMITTENT
MALFUNCTIONS . . . . . . . . . . . . . . . . . . . . 00-14
INSPECTION SERVICE POINTS
FOR A BLOWN FUSE . . . . . . . . . . . . . . . . 00-16
HOW TO TREAT CURRENT TROUBLE . . 00-16
HOW TO TREAT PAST TROUBLE . . . . . . 00-16
AFFILIATED DTC REFERENCE
TABLE . . . . . . . . . . . . . . . . . . . . . . . .00-17
VEHICLE IDENTIFICATION . . . . . . .00-18
VEHICLE IDENTIFICATION NUMBER . . . 00-18
VEHICLE INFORMATION NUMBER LIST 00-19
VEHICLE COMPLIANCE PLATE . . . . . . . . 00-19
VEHICLE DATA PLATE . . . . . . . . . . . . . . . 00-20
AUSTRALIAN DESIGN RULES . . . . . . . . . 00-20OPTION CODES . . . . . . . . . . . . . . . . . . . . . 00-21
EXPORT CODES . . . . . . . . . . . . . . . . . . . . 00-21
TYRE AND LOADING PLACARD . . . . . . . . 00-21
ENGINE MODEL STAMPING . . . . . . . . . . . 00-22
PRECAUTIONS BEFORE SERVICE .00-22
SUPPLEMENTAL RESTRAINT
SYSTEM (SRS . . . . . . . . . . . . . . . . . . . . . . 00-22
HOW TO PERFORM VEHICLE
IDENTIFICATION NUMBER (VIN) WRITING00-23
SERVICING ELECTRICAL SYSTEM . . . . . 00-24
VEHICLE WASHING . . . . . . . . . . . . . . . . . . 00-24
APPLICATION OF ANTI-CORROSION
AGENTS AND UNDERCOATS . . . . . . . . . . 00-25
DIAGNOSTIC TOOL (MUT-III) . . . . . . . . . . 00-25
TOWING AND HOISTING. . . . . . . . . .00-26
GENERAL DATA AND
SPECIFICATIONS . . . . . . . . . . . . . . .00-31
TIGHTENING TORQUE . . . . . . . . . . .00-32
LUBRICATION AND MAINTENANCE 00-34
RECOMMENDED LUBRICANTS AND
LUBRICANT CAPACITIES TABLE . .00-35
Continued on next page

GENERAL00-2
MAINTENANCE SERVICE . . . . . . . .00-37
1. FUEL SYSTEM (TANK, PIPE LINE AND
CONNECTION, AND FUEL TANK FILLER
TUBE CAP) (CHECK FOR LEAKS) . . . . . . 00-37
2. FUEL HOSES (CHECK CONDITION) . . 00-37
3. AIR CLEANER FILTER (REPLACE). . . . 00-37
4. EVAPORATIVE EMISSION SYSTEM
(EXCEPT EVAPORATIVE EMISSION
CANISTER) (CHECK FOR CLOGGING) . . 00-37
5. SPARK PLUGS (REPLACE). . . . . . . . . . 00-38
7. TIMING BELT (REPLACE) . . . . . . . . . . . 00-38
8. DRIVE BELTS (FOR ALTERNATOR, POWER
STEERING PUMP AND AIR CONDITIONING)
(CHECK) . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-39
9. EXHAUST SYSTEM (CONNECTIONS
PORTION OF MUFFLER, MUFFLER PIPES
AND CONVERTER HEAT SHIELDS) (CHECK
AND SERVICE AS REQUIRED) . . . . . . . . . 00-44
10. ENGINE OIL (CHANGE) . . . . . . . . . . . . 00-4411. ENGINE OIL FILTER (REPLACE) . . . . 00-44
12. TRANSMISSION FLUID . . . . . . . . . . . . 00-45
13. ENGINE COOLANT (CHANGE) . . . . . . 00-47
14. COOLANT HOSES (RADIATOR HOSE,
HEATER HOSE) (INSPECT). . . . . . . . . . . . 00-49
15. DISC BRAKE PADS, ROTORS
(INSPECT FOR WEAR) . . . . . . . . . . . . . . . 00-49
16. BRAKE HOSES (CHECK FOR
DETERIORATION OR LEAKS) . . . . . . . . . . 00-49
17. BALL JOINT AND STEERING LINKAGE
SEALS (INSPECT FOR GREASE LEAKS
AND DAMAGE) . . . . . . . . . . . . . . . . . . . . . . 00-50
18. DRIVE SHAFT BOOTS (INSPECT FOR
GREASE LEAKS AND DAMAGE) . . . . . . . . 00-50
19. SUSPENSION SYSTEM (INSPECT FOR
LOOSENESS AND DAMAGE) . . . . . . . . . . 00-51
20. SRS AIR BAG (INSPECT FOR SRS
SYSTEM). . . . . . . . . . . . . . . . . . . . . . . . . . . 00-51
21. TYRES (ROTATE). . . . . . . . . . . . . . . . . 00-58

HOW TO USE THIS MANUAL
GENERAL00-3
HOW TO USE THIS MANUALM1001000100897
MAINTENANCE, REPAIR AND
SERVICING EXPLANATIONS
This manual provides explanations, etc. concerning
procedures for the inspection, maintenance, repair
and servicing of the subject model. Unless otherwise
specified, each service procedure covers all models.
Procedures covering specific models are identified
by the model codes, or similar designation (engine
type, transaxle type, etc). A description of these des-
ignations is covered in this manual under &#34;VEHICLE
IDENTIFICATION.&#34;
.
ON-VEHICLE SERVICE
The &#34;ON-VEHICLE SERVICE&#34; section has proce-
dures for performing inspections and adjustments of
particularly important components. These proce-
dures are done with regard to maintenance and ser-
vicing, but other inspections (looseness, play,
cracking, damage, etc.) must also be performed.
.
SERVICE PROCEDURES
The service steps are arranged in numerical order.
Attention to be paid in performing vehicle service are
described in detail in SERVICE POINTS.
DEFINITION OF TERMS
.
STANDARD VALUE
Indicates the value used as the standard for judging
whether or not a part or adjustment is correct.
.
LIMIT
Shows the maximum or minimum value for judging
whether or not a part or adjustment is acceptable.
.
REFERENCE VALUE
Indicates the adjustment value prior to starting the
work (presented in order to facilitate assembly and
adjustment procedures, and so they can be com-
pleted in a shorter time).
.
DANGER, WARNING, AND CAUTION
DANGER, WARNING, and CAUTION call special
attention to a necessary action or to an action that
must be avoided. The differences among DANGER,
WARNING, and CAUTION are as follows:
If a DANGER is not followed, the result is severe
bodily harm or even death.
If a WARNING is not followed, the result could be
bodily injury.
If a CAUTION is not followed, the result could be
damage to the vehicle, vehicle components or
service equipment.
TIGHTENING TORQUE INDICATION
The tightening torque indicates a median and its tol-
erance by a unit of N
m (in-lb.) or Nm (ft.-lb.). For
fasteners with no assigned torque value, refer to
P.00-32.
SPECIAL TOOL NOTE
Only MMC special tool part numbers are called out in
the repair sections of this manual. Please refer to the
special tool cross-reference chart located at the
beginning of each group, for the special tool number
that is available in your market.
ABBREVIATIONS
The following abbreviations are used in this manual
for classification of model types:
A/T:Automatic transaxle, or models equipped with
automatic transaxle.
MPI: Multipoint fuel injection, or engines equipped
with multiport fuel injection.
A/C: Air conditioning.
3.8L engine: 3.8 litre <6G75> engine, or a model
equipped with such an engine.
ABS: Anti-lock Braking System
TCL: Traction Control System
ECU: Electronic Control Unit
V.C.I.: Vehicle Communication Interface
SWS: Simplified Wiring System
CAN: Controller Area Network
M/T: Manual Transmission
SRS: Supplemental Restraint System

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
GENERAL00-7
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE
POINTS
TROUBLESHOOTING CONTENTSM1001013300062
During diagnosis, a DTC code associated with
other system may be set when the ignition
switch is turned on with connector(s) discon-
nected. On completion, confirm all systems
for DTC code(s). If DTC code(s) are set, erase
them all.
When the DIAGNOSTIC TOOL (MUT-III)
detects a diagnostic trouble code, its display
informs users whether a mechanical problem
currently exists (“current trouble”) or whether
it existed before but normal operation has
been restored (“past trouble”). However, if an
MPI, TPMS or SRS airbag-related DTC is set,
“Active DTC/Stored DTC” is not displayed. In
this case, follow the diagnosis procedure for
current trouble.
If a trouble, detected in a CAN communica-
tion-capable system, can be reproduced,
diagnose the CAN bus lines (Refer to GROUP
54C, Can Bus Line Diagnostics Chart
P.54C-15 or P.54C-15).
Troubleshooting of electronic control systems for
which the MUT -III can be used follows the basic out-
line described below. Even in systems for which the
MUT-III cannot be used, part of these systems still
follow this outline.
1. STANDARD FLOW OF DIAGNOSTIC
TROUBLESHOOTING
Troubleshooting strategy is shown in each group.
2. SYSTEM OPERATION AND SYMPTOM
VERIFICATION TESTS
If verification of the symptom(s) is difficult, proce-
dures for checking operation and verifying symptoms
are shown.
3. DIAGNOSTIC FUNCTION
The following trouble code diagnoses are shown.
How to read diagnostic trouble codes
How to erase diagnostic trouble codes
Input inspection service points
4. DIAGNOSTIC TROUBLE CODE CHART
If the MUT-III displays a diagnostic trouble code, find
the applicable inspection procedure according to this
chart.
5. SYMPTOM CHART
If there are symptoms, even though the MUT-III
shows that no DTCs are set, inspection procedures
for each symptom will be found by using this chart.
6. DIAGNOSTIC TROUBLE CODE
PROCEDURES
Indicates the inspection procedures corresponding to
each diagnostic trouble code. (Refer to P.00-9).
7. SYMPTOM PROCEDURES
Indicates the inspection procedures corresponding to
each symptom listed in the Symptom Chart (Refer to
P.00-9).
8. SERVICE DATA REFERENCE TABLE
Inspection items and normal judgment values have
been provided in this chart as reference information.
9. CHECK AT ECU TERMINALS
Terminal numbers for the ECU connectors, inspec-
tion items, and standard values have been provided
in this chart as reference information.
.
TERMINAL VOLTAGE CHECKS
1. Use correct tool to check each pin location on the
ENGINE-ECU Check harnes MB992044 and
measure with voltmeter.
Short-circuiting the positive (+) test probe
between a connector terminal and ground could
damage the vehicle wiring, the sensor, the ECU,
or all three. Use care to prevent this!
2. Insert the correct terminal tool into each of the
ENGINE-ECU check harness connector
terminals, and measure the voltage while referring
to the check chart.
NOTE: Measure voltage with the ECU connectors
connected.
You may find it convenient to pull out the ECU to
make it easier to connect the ENGINE-ECU check
harness.