Plug MITSUBISHI 380 2005 Workshop Manual

HEADLINING
INTERIOR52A-19
HEADLINING
REMOVAL AND INSTALLATIONM1521001400360
Pre-removal and Post-installation Operation
Front Seat Assembly (Refer to P.52A-21.)
Removal and Installation of Rear Seat Cushion Assembly
and Rear Seatback Assembly (Refer to P.52A-55.)
Removal and Installation of Front Pillar Trim, Center Pillar
Trim Upper and Rear Pillar Trim (Refer to P.52A-11.)
REMOVAL STEPS
1. SUN VISOR
2. SUN VISOR HOLDER
3. OVERHEAD CONSOLE
ASSEMBLY
4. DOME LIGHT ASSEMBLY (REFER
TO GROUP 54A, DOME LIGHT
P.54A-163.)
5. ASSIST GRIP PLUG
6. ROOF INSIDE ASSIST GRIP
<VEHICLES WITH ROOF INSIDE
ASSIST GRIP>
7. SUNROOF OPENING TRIM
<VEHICLES WITH SUNROOF>8. ROOF HARNESS CLAMP
INSTRUMENT PANEL SIDE
COVER (REFER TO P.52A-4.)
9. ROOF HARNESS CONNECTOR
FLOOR CONSOLE ASSEMBLY
(REFER TO P.52A-10.)
PARKING BRAKE LEVER
ASSEMBLY MOUNTING BOLT
(REFER TO GROUP 36, PARKING
BRAKE LEVER P.36-6.)
<<A>>10. HEADLINING ASSEMBLY
11. OVERHEAD CONSOLE BRACKET
12. FRONT HEADLINING PAD REMOVAL STEPS (Continued)

HEATER UNIT, HEATER CORE, BLOWER ASSEMBLY AND EVAPORATOR UNIT
HEATER, AIR CONDITIONING AND VENTILATION55-152
REMOVAL SERVICE POINTS
.
<<A>> SUCTION PIPE AND LIQUID PIPE DISCON-
NECTION
As the compressor oil and receiver are highly moisture
absorbent, use a non-porous material to plug the hose and
nipples.
To prevent the entry of dust or other foreign bodies, plug the
dismantled hose and the nipples of the expansion valves.
.
<<B>> HEATER UNIT AND DECK
CROSSMEMBER ASSEMBLY REMOVAL
Disconnect the following connectors to gain access to the front
deck crossmember.
6. ETACS-ECU
<<B>>7. HEATER UNIT AND DECK
CROSSMEMBER ASSEMBLY REMOVAL STEPS (Continued)
Connector
numberConnector name
C-113 AUDIO AMPLIFIER
C-114 AUDIO AMPLIFIER
C-25 FRONT WIRING HARNESS AND FLOOR
WIRING HARNESS COMBINATION
C-26 INSTRUMENT PANEL WIRING HARNESS
AND FRONT DOOR WIRING HARNESS (LH)
COMBINATION
C-27 INSTRUMENT PANEL WIRING HARNESS
AND ROOF WIRING HARNESS
COMBINATION
C-28 INSTRUMENT PANEL WIRING HARNESS
AND FLOOR WIRING HARNESS
COMBINATION
C-29 INSTRUMENT PANEL WIRING HARNESS
AND FRONT WIRING HARNESS
COMBINATION
C-30 STOPLIGHT SWITCH
C-07 CLUTCH PEDAL SWITCH

COMPRESSOR ASSEMBLY AND DRIVE BELT
HEATER, AIR CONDITIONING AND VENTILATION55-165
REMOVAL SERVICE POINTS
.
<<A>> FLEXIBLE SUCTION HOSE AND FLEXIBLE
DISCHARGE HOSE DISCONNECTION
As the compressor oil and receiver are highly moisture
absorbent, use a non-porous material to plug the hose and
nipples.
To prevent the entry of dust or other foreign bodies, plug the
dismantled hoses and compressor nipples.
.
<<B>> COMPRESSOR REMOVAL
Take care not to spill any compressor oil when removing the
compressor.
INSTALLATION SERVICE POINT
.
>>A<< FLEXIBLE SUCTION HOSE CONNECTION
To prevent mis-alignment of suction hose to bracket use the
folowing assembly procedure.
1. Insert hoseconnector into compressor and hand start bolt.
2. Assemble P-clip to hose and suction hose bracket. Tighten
bolt.
3. Tighten bolt between compressor and hose connector.
.
>>B<< COMPRESSOR INSTALLATION
If a new compressor is installed, first adjust the amount of oil
according to the procedures described below, and then install
the compressor.
1. Measure the amount (X ml) of oil within the removed
compressor.
2. Drain (from the new compressor) the amount of oil
calculated according to the following formula, and then
install the new compressor.
New compressor oil amount = 140 ml
140 ml
X ml = Y ml
NOTE: Y ml indicates the amount of oil in the refrigerant line,
the condenser, the evaporator, etc.
NOTE: When replacing the following parts at the same times as
the compressor, subtract the rated oil amount of each part from
Y ml and discharge from the new compressor.
Compressor oil: ND Oil 8
Quantity:
Evaporator: 40 ml
Condenser: 40 ml
Receiver: 40 ml

CONDENSER AND CONDENSER FAN
HEATER, AIR CONDITIONING AND VENTILATION55-168
REMOVAL SERVICE POINTS
.
<<A>> FLEXIBLE SUCTION HOSE AND LIQUID
PIPE A DISCONNECTION
As the compressor oil and receiver are highly moisture
absorbent, use a non-porous material to plug the hose and
nipples.
To prevent the entry of dust or other foreign bodies, plug the
dismantled hose and condenser assembly nipples.
INSTALLATION SERVICE POINT
.
>>A<< DRYER REMOVAL PROCEDURE
1. Remove the condenser assembly from the vehicle to access
the modulator.
2. Remove the modulator cap using a14 mm hexagon wrench.
3. Remove the desiccant bag from the modulator.
Do not remove the desiccant bag from the plastic bag until
just before inserting it into the modulator.
.
<<B>> DRYER REPLACEMENT PROCEDURE
1. Fit the desiccant bag with the welded portion facing the
bottom of the modulator towards the screw-thread end.
2. Add 40 ml of ND Oil 8 into system to balance the oil
removed from the system.
3. Tighten the cap to the required torque.
2.9
1.0 Nm
Because the plastic cap has a large, 14 mm hex socket, it
is susceptible to generating excessive torque. Therefore,
be careful not to damage the crown portion of the cap.
.
<<B>> >>A<<6. CAP WITH FILTER
<<B>> >>A<<7. DESICCANT BAG
FRONT UNDER COVER
RADIATOR GRILLES
FRONT END STRUCTURE BAR
CONDENSER FAN REMOVAL
STEPS
8. CONDENSER FAN ASSEMBLY
9. RADIATOR AND FAN ASSEMBLYCONDENSER REMOVAL STEPS

REFRIGERANT LINE
HEATER, AIR CONDITIONING AND VENTILATION55-171
REMOVAL SERVICE POINT
.
<<A>> HOSE/PIPE DISCONNECTION
As the compressor oil and receiver are highly moisture
absorbent, use a non-porous material to plug the hose and
nipples.
To prevent the entry of other foreign bodies, plug the con-
denser, compressor, and expansion valve nipples.
.
<<B>> SUCTION PIPE AND SUCTION FLEXIBLE
HOSE DISCONNECTION
As the compressor oil and receiver are highly moisture
absorbent, use a non-porous material to plug the hose and
nipples.
To disconnect the suction hose from the suction flexible hose,
loosen the union nut on the suction pipe counterclockwise until
nut is completely disengaged from suction hose thread .
Plug the hose nipple to prevent entry of dust and dirt.
INSTALLATION SERVICE POINT
.
>>A<< SUCTION HOSE INSTALLATION
1. When replacing the suction hose, refill them with a specified
amount of compressor oil, and then install them.
2. Ensure o-ring is installed correctly and lubricated then fit
suction hose into suction pipe fitting. With suitable tools hold
the suction hose fitting while tightening union nut to
specified torque.

ON-VEHICLE SERVICE
ENGINE COOLING14-27
RADIATOR CAP PRESSURE CHECKM1141001300419
NOTE: Be sure that the cap is clean before testing. Rust or
other foreign material on the cap seal will cause an improper
reading.
1. Use a cap adapter to attach the cap to the tester.
2. Increase the pressure until the indicator of the gauge stops
moving.
Minimum limit: 83 kPa (12 psi)
Standard value: 93
123 kPa (14 18 psi)
3. Replace the radiator cap if the reading does not remain at or
above the limit.
ENGINE COOLANT REPLACEMENTM1141001200478
When removing the radiator cap, use care to avoid
contact with hot coolant or steam. Place a shop towel
over the cap and turn the cap counterclockwise a lit-
tle to let the pressure escape through the vinyl tube.
After relieving the steam pressure, remove the cap by
slowly turning it counterclockwise.
1. Drain the water from the radiator, heater core and engine
after unplugging the radiator drain plug and removing the
radiator cap.

ON-VEHICLE SERVICE
ENGINE COOLING14-28
2. Drain the water in the water jacket by unplugging the drain
plug of the cylinder block.
3. Remove the radiator condenser tank assembly and drain the
coolant.
4. Drain the coolant then clean the path of the coolant by
injecting water into the radiator from the radiator cap area.
5. Apply the designated sealant to the screw area of the
cylinder block drain plug, and then tighten to the standard
torque.
Specified sealant: 3M
AAD Part No.8731 or equiva-
lent
Tightening torque:
39
5 Nm
6. Securely tighten the radiator drain plug.
7. Assemble the radiator condenser tank assembly.

RADIATOR
ENGINE COOLING14-34
REMOVAL SERVICE POINTS
.
<<A>> RADIATOR UPPER HOSE/RADIATOR
LOWER HOSE DISCONNECTION
Make mating marks on the radiator hose and the hose clamp.
Disconnect the radiator hose.
.
<<B>> A/T OIL COOLER HOSE REMOVAL
After removing the hose from the radiator, plug the hose and
the radiator nipple to prevent dust or foreign particles from get-
ting in.
INSTALLATION SERVICE POINT
.
>>A<< RADIATOR LOWER HOSE/RADIATOR
UPPER HOSE CONNECTION
1. Insert each hose as far as the projection of the water inlet
fitting.
2. Align the mating marks on the radiator hose and hose
clamp, and then connect the radiator hose.

SPECIFICATIONS
ENGINE COOLING14-42
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONSM1141005000346
ITEM SPECIFICATION
Cylinder block drain plug 39
5 Nm (29 3 ft-lb)
Radiator
Front end structure bar bolt M8
10 11 2 Nm (98 17 in-lb)
M8
20 22 4 Nm (16 3 ft-lb)
Thermostat
Control harness bolt 5.0
1.0 Nm (44 9 in-lb)
Grounding bolt M6 9.0
2.0 Nm (80 17 in-lb)
M8 22
4 Nm (16 3 ft-lb)
Water inlet fitting bolt 19
1 Nm (14 1 ft-lb)
Water hose and water pipe
Engine coolant temperature sensor 29
10 Nm
Thermostat housing bolt 19
1 Nm (14 1 ft-lb)
Water pump inlet pipe 11
1 Nm (98 8 ft-lb)
Water pump
Water pump bolt M8 42
8 Nm (31 6 ft-lb)
M10 24
3 Nm (18 2 ft-lb)
Water pump bracket bolt 24
3 Nm (18 2 ft-lb)

SPECIFICATIONS
ENGINE COOLING14-43
SERVICE SPECIFICATIONM1141000300449
CAPACITIESM1141005100138
SEALANTSM1141000500368
ITEM STANDARD VALUE LIMIT
Fan Controller V A/C OFF 1 or less -
A/C ON Repeat
8.2
2.6
System voltage
2.6-
High-pressure valve opening pressure of radiator cap kPa (psi) 93
123 (14 18) Minimum 83 (12)
Thermostat Valve opening temperature
of thermostat
C (F)3.8L Engine 88
1.5 (190 3)
-
Full-opening temperature
of thermostat
C (F)3.8L Engine 100 (212)
-
Valve lift mm (in) 3.8L Engine 9.0 (0.35) or more
-
ITEM
QUANTITY dm3 (qt)
Long life antifreeze coolant or an equivalent 3.8L Engine 8.7 (9.2)
ITEM SPECIFIED SEALANT
Cylinder block drain plug 3M
AAD Part No.8731 or equivalent
Engine coolant temperature sensor