service MITSUBISHI 380 2005 Workshop Manual

WATER HOSE AND WATER PIPE
ENGINE COOLING14-41
INSTALLATION SERVICE POINTS
.
>>A<< O-RING INSTALLATION
Do not allow engine oil or other grease to adhere to the
O-ring
Insert the O-ring to the water pipe, and coat the outer portion of
the O-ring with water or engine coolant.
.
>>B<< ENGINE COOLANT TEMPERATURE
SENSOR INSTALLATION
Apply the specified sealant to the thread of the engine coolant
temperature sensor, and then tighten it to the specified torque.
Specified Sealant: 3M
AAD Part No. 8731 or equiva-
lent
.
>>C<< RADIATOR UPPER HOSE CONNECTION
1. Insert each hose as far as the projection of the water outlet
fitting.
2. Align the mating marks on the radiator hose and hose
clamp, and then connect the radiator hose.
INSPECTIONM1141003400337.
Water Pipe and Hose Check
Check the water pipe and hose for cracks, damage and clogs.
Replace them if necessary.

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

15-1
GROUP 15
INTAKE AND
EXHAUST
CONTENTS
GENERAL DESCRIPTION. . . . . . . . .15-2
INTAKE AND EXHAUST DIAGNOSIS15-2
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . 15-2
TROUBLESHOOTING STRATEGY . . . . . . 15-2
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 15-2
SYMPTOM PROCEDURES . . . . . . . . . . . . 15-2
SPECIAL TOOLS . . . . . . . . . . . . . . . .15-3
AIR CLEANER . . . . . . . . . . . . . . . . . .15-4
REMOVAL AND INSTALLATION . . . . . . . . 15-4
INTAKE MANIFOLD PLENUM . . . . .15-5
REMOVAL AND INSTALLATION . . . . . . . 15-5
INTAKE MANIFOLD . . . . . . . . . . . . . .15-7
REMOVAL AND INSTALLATION . . . . . . . . 15-7
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 15-9
EXHAUST MANIFOLD . . . . . . . . . . . .15-10
REMOVAL AND INSTALLATION . . . . . . . . 15-10
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 15-13
EXHAUST PIPE AND MAIN MUFFLER15-14
REMOVAL AND INSTALLATION . . . . . . . . 15-14
SPECIFICATIONS . . . . . . . . . . . . . . .15-16
FASTENER TIGHTENING SPECIFICATIONS15-16
SERVICE SPECIFICATION . . . . . . . . . . . . 15-18
SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . 15-18

SPECIAL TOOLS
INTAKE AND EXHAUST15-3
INSPECTION PROCEDURE 2: Abnormal Noise
DIAGNOSIS
STEP 1. Start the engine. Have an assistant stay
in the drivers seat. Raise the vehicle on a hoist.
Have the assistant rev the engine while
searching for exhaust leaks.
Q: Is any abnormal noise generated?
YES :
Go to Step 2.
NO : The procedure is complete.
STEP 2. Check for missing parts in the muffler.
Tap the muffler lightly to check for loose baffles,
etc.
Q: Are there any missing parts in the muffler?
YES :
Replace, then go to Step 1.
NO : Go to Step 3.
STEP 3. Check the hanger for cracks.
Q: Is the hanger cracked?
YES :
Replace, then go to Step 1.
NO : Go to Step 4.
STEP 4. Check for interference of the pipes and
muffler with the body.
Q: Are the pipes and muffler interfering with the
body?
YES :
Repair, then go to Step 1.
NO : Go to Step 5.
STEP 5. Check the heat protectors.
Q: Are any heat protectors loose or damaged?
YES :
Tighten or replace, then go to Step 1.
NO : Go to Step 6.
STEP 6. Check the pipes and muffler for damage.
Q: Are the pipes and muffler damaged?
YES :
Replace, then go to Step 1.
NO : There is no action to be taken.
SPECIAL TOOLSM1151000600429
TOOL TOOL NUMBER AND
NAMESUPERSESSION APPLICATION
MD998412
GuideMD998412 Installation of intake
manifold plenum
MB991953
Oxygen sensor wrench- Removal and installation
of heated oxygen sensor
MD998770
Oxygen sensor wrenchMD998770-01 or General
service toolRemoval and installation
of heated oxygen sensor

INTAKE MANIFOLD PLENUM
INTAKE AND EXHAUST15-5
INTAKE MANIFOLD PLENUM
REMOVAL AND INSTALLATION M1151002700198
Pre-removal Operation
Engine Coolant Draining (Refer to GROUP 14, On-vehicle
Service P.14-27).
Strut Tower Bar Removal (Refer to GROUP 42, Strut
To w e r B a r P.42-12).
Air Cleaner Cover and Air Intake Hose Removal (Refer to
P.15-4).
Throttle Body Removal (Refer to GROUP 13B, Throttle
Body 13A-674).Post-installation Operation
Throttle Body Installation (Refer to GROUP 13B, Throttle
Body 13A-674).
Air Cleaner Cover and Air Intake Hose Installation (Refer
to P.15-4).
Strut Tower Bar Installation (Refer to GROUP 42, Strut
Tower Bar P.42-12).
Engine Coolant Supplying (Refer to GROUP 14, On-vehi-
cle Service P.14-27).

INTAKE MANIFOLD PLENUM
INTAKE AND EXHAUST15-6
Required Special Tool:
MD998412: Guide
INSTALLATION SERVICE POINT
.
>>A<< INTAKE MANIFOLD PLENUM INSTALLA-
TION
Use special tool MD998412 to install the intake manifold ple-
num.
REMOVAL STEPS
1. MANIFOLD ABSOLUTE
PRESSURE SENSOR
CONNECTOR
2. CONTROL WIRING HARNESS
AND INJECTOR WIRING
HARNESS COMBINATION
CONNECTOR
3. CRANKSHAFT POSITION
SENSOR CONNECTOR
4. KNOCK SENSOR CONNECTOR
5. POWER STEERING PRESSURE
SWITCH CONNECTOR
6. EVAPORATIVE EMISSION
PURGE SOLENOID CONNECTOR
8. VACUUM HOSE CONNECTION
9. PURGE HOSE
10. POWER STEERING PRESSURE
HOSE CLAMP
11. POWER STEERING PRESSURE
HOSE CLAMP BRACKET
12. INTAKE MANIFOLD PLENUM
STAY, REARSTEERING GEAR AND LINKAGE
PROTECTOR (REFER TO 37,
STEERING GEAR BOX AND
LINKAGE P.37-30)
POWER STEERING OIL PUMP
(REFER TO 37, POWER
STEERING OIL PUMP ASSEMBLY
P.37-43)
15. POWER STEERING OIL PUMP
BRACKET CONNECTING BOLT
16. INTAKE MANIFOLD PLENUM
STAY, FRONT
>>A<<17. INTAKE MANIFOLD PLENUM
18. INTAKE MANIFOLD PLENUM
GASKET
19. VACUUM PIPE
20. EVAPORATIVE EMISSION
PURGE SOLENOID ASSEMBLY
23. HARNESS BRACKET
24. MANIFOLD ABSOLUTE
PRESSURE SENSOR
25. O-RINGREMOVAL STEPS (Continued)

INTAKE MANIFOLD
INTAKE AND EXHAUST15-7
INTAKE MANIFOLD
REMOVAL AND INSTALLATION M1151003000802
Pre-removal Operation
Fuel Discharge Prevention [Refer to GROUP 13B,
On-vehicle Service
Fuel Pump Relay Disconnection
(How to Reduce Pressurized Fuel Lines) 13A-663.]
Intake Manifold Plenum Removal (Refer to P.15-5.)Post-installation Operation
Intake Manifold Plenum Installation (Refer to P.15-5.)
Fuel Leakage Inspection
REMOVAL STEPS
1. INJECTOR CONNECTOR
2. ENGINE MOUNTING STAY
>>C<<3. FUEL HIGH-PRESSURE HOSE
CONNECTION
5. BLOW-BY HOSE
<>6. FUEL RAIL AND INJECTOR
7. PCV HOSE CONNECTION8. TIMING BELT FRONT UPPER
COVER, RIGHT
9. TIMING BELT FRONT UPPER
COVER, LEFT
10. WATER PUMP BRACKET>>B<<11. INTAKE MANIFOLD
>>A<<12. INTAKE MANIFOLD GASKET
13. CONTROL HARNESS CLAMPREMOVAL STEPS (Continued)

INTAKE MANIFOLD
INTAKE AND EXHAUST15-8
REMOVAL SERVICE POINT
.
<> FUEL RAIL AND INJECTOR REMOVAL
Care must be taken when removing the fuel rail not to drop
the injector.
Remove the fuel rail with the injectors attached to it.
INSTALLATION SERVICE POINTS
.
>>A<< INTAKE MANIFOLD GASKET INSTALLA-
TION
Install the gasket with the protrusions in the position illustrated.
.
>>B<< INTAKE MANIFOLD INSTALLATION
1. Coat the intake manifold mounting studs with engine oil.
2. Tighten the intake manifold mounting nuts by the following
procedure.
.
ORDER MOUNTING NUTS TIGHTENING TORQUE
1st Right-bank nuts 6.5
1.5 Nm (58 13 in-lb)
2nd Left-bank nuts 22
1 Nm (16 1 ft-lb)
3rd Right-bank nuts 22
1 Nm (16 1 ft-lb)
4th Left-bank nuts 22
1 Nm (16 1 ft-lb)
5th Right-bank nuts 22
1 Nm (16 1 ft-lb)

EXHAUST MANIFOLD
INTAKE AND EXHAUST15-11

Required Special Tools:
MB991953: Oxygen Sensor WrenchMD998770: Oxygen Sensor Wrench
Pre-removal and Post-installation Operation
Air Cleaner Cover and Air Intake Duct Removal and
Installation (Refer to P.15-4).
Battery Removal and Installation
Under Cover Removal and Installation (Refer to GROUP
51, Under Cover P.51-13).
Front Exhaust Pipe, Center Exhaust Pipe Removal and
Installation (Refer to P.15-14).
Strut Tower Bar Removal and Installation (Refer to
GROUP 42, Strut Tower Bar P.42-12).
Engine Coolant Draining and Refilling (Refer to GROUP
14, On-vehicle Service Engine Coolant Replacement
P.14-27).
REMOVAL STEPS
1.
CENTER UNDER FLOOR HEAT
PROTECTOR
STEERING GEAR AND LINKAGE
PROTECTOR (REFER TO GROUP 37,
POWERSTEERING GEAR BOX AND
LINKAGE
P.37-30)
2.FRONT UNDER FLOOR HEAT
PROTECTOR
3.EXHAUST MANIFOLD STAY, RIGHT A
4.RIGHT BANK HEATED OXYGEN
SENSOR (FRONT) CONNECTOR
5.RIGHT BANK HEATED OXYGEN
SENSOR (REAR) CONNECTOR
<> >>A<<6.RIGHT BANK HEATED OXYGEN
SENSOR (FRONT)
<> >>A<<7.RIGHT BANK HEATED OXYGEN
SENSOR (REAR)
10.UPPER HEAT PROTECTOR
11 .EXHAUST MANIFOLD STAY, RIGHT B
12.EXHAUST MANIFOLD
13.EXHAUST MANIFOLD GASKET
REMOVAL STEPS (Continued)

EXHAUST MANIFOLD
INTAKE AND EXHAUST15-12
REMOVAL SERVICE POINTS
.
<> LEFT BANK HEATED OXYGEN SENSOR
(FRONT)/RIGHT BANK HEATED OXYGEN SEN-
SOR (FRONT)/RIGHT BANK HEATED OXYGEN
SENSOR (REAR) REMOVAL
Use special tool MD998770 to remove the heated oxygen sen-
sor.
.
<> LEFT BANK HEATED OXYGEN SENSOR
(REAR) REMOVAL
Use special tool MB991953 to remove the heated oxygen sen-
sor.
INSTALLATION SERVICE POINTS
.
>>A<< RIGHT BANK HEATED OXYGEN SENSOR
(REAR)/RIGHT BANK HEATED OXYGEN SENSOR
(FRONT)/LEFT BANK HEATED OXYGEN SENSOR
(FRONT) INSTALLATION
Use special tool MD998770 to install the heated oxygen sen-
sor.
.