air condition MITSUBISHI 380 2005 Workshop Manual

CHARGING SYSTEM
ENGINE ELECTRICAL16-10
REGULATED VOLTAGE TESTM1161001100666
Required Special Tools:
: Diagnostic Tool (MUT-III)
MB991824: V.C.I.
MB991827: MUT-III USB Cable
MB991910: MUT-III Main Harness A
MB998467: Alternator Harness Connector
This test determines whether the voltage regulator is
correctly controlling the alternator output voltage.
Battery posts, terminals and related acces-
sories contain lead and lead compounds.
WASH HANDS AFTER HANDLING.
1. Always be sure to check the following before the
test:
Alternator installation
Check to be sure that the battery installed in the
vehicle is fully charged. (Refer to GROUP 54A,
Chassis Electrical
Battery On-vehicle Service
Battery Check P.54A-5.)
Alternator drive belt tension (Refer to GROUP 00,
General
Maintenance Service Drive Belts
(For Alternator, Power Steering Pump and Air
Conditioning) (Check) P.00-39.)
Fusible link
Abnormal noise from the alternator while the
engine is running.2. Turn the ignition switch to the "LOCK" (OFF)
position.
3. Disconnect the negative battery cable.
4. Use the special tool (Alternator harness
connector: MB998467) to connect a digital-type
voltmeter between the alternator "S" terminal and
ground. (Connect the positive lead of the
voltmeter to the "S" terminal, and then connect the
negative lead of the voltmeter to a secure ground
or to the negative battery terminal.)
5. Connect a clamp-type DC test ammeter with a
range of 0
120 A to the alternator "B" terminal
output wire.
6. Reconnect the negative battery cable.
7. Connect an engine tachometer, or diagnostic tool.
8. Turn the ignition switch to the "ON" position and
check that the reading on the voltmeter is equal to
the battery positive voltage.
NOTE: If the voltage is 0 V, the cause is probably
an open circuit in the wire or fusible link between
the alternator "S" terminal and the battery positive
terminal or malfunctioning voltmeter.
9. Check to be sure that all lights and accessories
are off.
10.Start the engine.

STARTING SYSTEM
ENGINE ELECTRICAL16-22
STEP 3.
Check the cable between starter B (battery) terminal and
battery positive terminal for connection and continuity.
Q: Is the starter cable in good condition?
YES : Go to Step 4.
NO : Repair or replace the cable.
STEP 4.
Check the connection and the continuity of the cable
between the starter motor body and the negative battery
terminal.
Q: Is the ground wire in good condition?
YES : Go to Step 5.
NO : Repair or replace the cable.
STEP 5.
Q: Is the starter motor in good condition? (Refer to Starting
System
Starter Motor Assembly Inspection P.16-17.)
YES : Excessive rotational resistance of the engine.
NO : Replace the starter motor.

CROSSMEMBER
POWER PLANT MOUNT32-9
CROSSMEMBER
REMOVAL AND INSTALLATIONM1321003200551
Before removing the steering wheel and air bag module assembly, always refer to GROUP 52B -
Service Precautions (P.52B-16), Air bag Module and Clock Spring (P.52B-237). Also, set the front
wheels so that they are facing straight forward, and remove the ignition key. If you fail to do this,
the SRS clock spring will be damaged, causing the SRS air bag to be inoperative and serious
injury.
*1: Indicates parts which should be initially tightened, and then fully tightened after placing the
vehicle horizontally and loading the full weight of the engine on the vehicle body.
*2: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle
on the ground in the unladen condition.
Pre-removal Operation
Power Steering Fluid Draining (Refer to GROUP 37,
On-vehicle Service Fluid Replacement P.37-18).
Power Steering Hoses Removal and Installation (Refer to
GROUP 37, Power Steering Hoses P.37A-57).
Air Bag Module and Steering Wheel Assembly Removal
(Refer to GROUP 37, Steering Wheel P.37-23).
Clock Spring Removal (Refer to GROUP 52B, Air Bag
Module and Clock Spring P.52B-237).
Floor Console Assembly Removal (Refer to GROUP 52A,
Floor Console Assembly P.52A-10).
Front Scuff Plate (LH) and Cowl Side Trim (LH) Removal
(Refer to GROUP 52A, Trims P.52A-11).
Trunk Lid Release Handle Cover Removal (Refer to
GROUP 42, Trunk Lid P.42-63).
Accelerator Stopper Removal (Refer to GROUP 17,
Accelerator Pedal P.17-9).
Front Floor Carpet Removal
Centremember Removal (Refer to P.32-7).Post-installation Operation
Centremember Installation (Refer to P.32-7).
Front Floor Carpet Installation
Accelerator Stopper Installation (Refer to GROUP 17,
Accelerator Pedal P.17-9).
Trunk Lid Release Handle Cover Installation (Refer to
GROUP 42, Trunk Lid P.42-63).
Front Scuff Plate (LH) and Cowl Side Trim (LH) Installa-
tion (Refer to GROUP 52A, Trims P.52A-11).
Floor Console Assembly Installation (Refer to GROUP
52A, Floor Console Assembly P.52A-10).
Clock Spring Installation (Refer to GROUP 52B, Air Bag
Module and Clock Spring P.52B-237).
Steering Wheel Assembly and Air Bag Module Installation
(Refer to P.37-23).
Check the dust cover for cracks or damage by pushing it
with your finger.
Power Steering Fluid Supplying (Refer to GROUP 37,
On-vehicle Service Fluid Replacement P.37-18).
Power Steering Fluid Line Bleeding (Refer to P.37-18).
Checking Steering Wheel Position with Wheels Straight
Ahead.
Front Wheel Alignment Adjustment (Refer to GROUP 33,
On-vehicle Service
Front Wheel Alignment Check and
Adjustment P.33-6).

WINDOW GLASS
BODY42-14
WINDOW GLASS DIAGNOSIS
INTRODUCTION TO WINDOW GLASS DIAGNOSISM1422006700254
If water emerges from the following points, there is a
problem in the seal or body flange.Windshield
Rear window glass
WINDOW GLASS DIAGNOSTIC TROUBLESHOOTING STRATEGYM1422006800240
Use these steps to plan your diagnostic strategy. If
you follow them carefully, you will be sure that you
have exhausted most of the possible ways to find a
window glass fault.
1. Gather information from the customer.2. Verify that the condition described by the
customer exists.
3. Find the malfunction by following the Symptom
Chart.
4. Verify malfunction is eliminated.
WINDOW GLASS DIAGNOSTIC TROUBLE SYMPTOM CHARTM1422006900281
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Water Leak Through Windshield/Rear Window Glass
DIAGNOSIS
STEP 1. Check if the seal is faulty.
Q: Is the seal faulty?
YES :
Repair the seal, then go to Step 3.
NO : Go to Step 2.
STEP 2. Check if the body flange is deformed.
Q: Is the body flange deformed?
YES :
Replay the body flange, then go to Step 3.
NO : Go to Step 3.
STEP 3. Retest the system.
Q: Is any water leaking?
YES :
Return to Step 1.
NO : This diagnosis complete.
SPECIAL TOOLM1422000600301
SYMPTOM INSPECTION
PROCEDUREREFERENCE PAGE
Water leak through windshield 1
P.42-14
Water leak through rear window glass
TOOL TOOL NUMBER AND
NAMESUPERSESSION APPLICATION
MB990480 Glass holder General service tool Removal and installation
of window glass

DOOR
BODY42-24
SYMPTOM CHARTM1423007000303
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Water Leak Through Door Window Glass
DIAGNOSIS
STEP 1. Check the window glass runchannel.
Q: Is the window glass runchannel in good condition?
YES :
Go to Step 2.
NO : Replace the runchannel, then go to Step 4.
STEP 2. Check the door window glass
installation.
Q: Is the door window glass installed correctly?
YES :
Go to Step 3.
NO : Reinstall the door window glass. (Refer to
P.42-39). Then go to Step 4.
STEP 3. Check the clearance at the top of the
door window glass.
Q: Is the clearance at the top of the door window
glass correct?
YES :
Go to Step 4.
NO : Adjust the door window glass. Refer to
P.42-31. Then go to Step 4.
STEP 4. Retest the system.
Q: Is any water leaking?
YES :
Return to Step 1.
NO : The procedure is complete.
INSPECTION PROCEDURE 2: Door Window Glass Malfunction
DIAGNOSIS
STEP 1. Check the door window glass
installation condition.
Q: Is the door window installed correctly?
YES :
Go to Step 2.
NO : Reinstall the door window glass. (Refer to
P.42-39). Then go to Step 4.
STEP 2. Check the door sash.
Q: Is the door sash in good condition?
YES :
Go to Step 3.
NO : Repair or replace door sash, then go to Step
4. SYMPTOM INSPECTION
PROCEDUREREFERENCE PAGE
Water leak through door window glass 1
P.42-24
Door window glass malfunction 2
P.42-24
Water leak through door edge 3
P.42-25
Water leak from door center 4
P.42-25
Door hard to open 5
P.42-25
Door does not open or close completely 6
P.42-26
Uneven gap between body 7
P.42-26
Wind noise around door 8
P.42-26

DOOR
BODY42-25
STEP 3. Inspect the window regulator assembly.
Q: Is the window regulator assembly in good
condition?
YES :
Go to Step 4.
NO : Repair or replace the window regulator
assembly, then go to Step 4.
STEP 4. Retest the system.
Q: Does the door window operate correctly?
YES :
The procedure is complete.
NO : Return to Step 1.
INSPECTION PROCEDURE 3: Water Leak Through Door Edge
DIAGNOSIS
STEP 1. Check the weatherstrip.
Q: Is the weatherstrip in good condition?
YES :
Go to Step 2.
NO : Replace the weatherstrip, then go to Step 3.
STEP 2. Check the door fit (alignment).
Q: Is the door fit (alignment) correct?
YES :
Go to Step 3.
NO : Adjust the door fit (Refer to P.42-30). Then
go to Step 3.
STEP 3. Retest the system.
Q: Is any water leaking?
YES :
Return to Step 1.
NO : The procedure is complete.
INSPECTION PROCEDURE 4: Water Leak from Door Center
DIAGNOSIS
STEP 1. Check the drain hole.
Q: Is the drain hole clogged?
YES :
Clean the drain hole, then go to Step 3.
NO : Go to Step 2.
STEP 2. Check the weatherstrip.
Q: Is the weatherstrip in good condition?
YES :
Go to Step 3.
NO : Repair or replace the weatherstrip, then go
to Step 3.
STEP 3. Retest the system.
Q: Is any water leaking?
YES :
Return to Step 1.
NO : The procedure is complete.
INSPECTION PROCEDURE 5: Door Hard to Open
DIAGNOSIS
STEP 1. Adjust the latch and striker engagement.
Refer to P.42-30.
Q: Is the latch and striker engagement adjusted?
YES :
Go to Step 2.
NO : Adjust the latch and striker. (Refer to
P.42-30). Then go to Step 4.
STEP 2. Check for lock cable damage.
Q: Is the lock rod damaged?
YES :
Repair or replace the lock cable, then go to
St e p 4.
NO : Go to Step 3.

DOOR
BODY42-26
STEP 3. Check the door handle flexibility
(amount of movement of handle required to open
door).
Q: Is the door handle flexibility good?
YES :
Go to Step 4.
NO : Check the door outside handle and inside
handle (Refer to P.42-35 and P.42-35).
Then go to Step 4.
STEP 4. Retest the system.
Q: Does the door open easily?
YES :
The procedure is complete.
NO : Return to Step 1.
INSPECTION PROCEDURE 6: Door Does Not Open or Close Completely
DIAGNOSIS
STEP 1. Check the door hinge position.
Q: Is the door hinge correct?
YES :
Go to Step 2.
NO : Adjust the door hinge (Refer to P.42-30).
Then go to Step 4.
STEP 2. Check the door for damage.
Q: Is the door in good condition?
YES :
Go to Step 3.
NO : Repair or replace the door, then go to Step
4.
STEP 3. Check lubrication.
Q: Are the door check and door hinge sufficiently
lubricated?
YES :
Go to Step 4.
NO : Apply grease, then go to Step 4.
STEP 4. Retest the system.
Q: Does the door open and close completely?
YES :
The procedure is complete.
NO : Return to Step 1.
INSPECTION PROCEDURE 7: Uneven Gap Between Body
.DIAGNOSIS
Adjust the door fit (Refer to P.42-30). Then check
that the gap has been improved.
INSPECTION PROCEDURE 8: Wind Noise Around Door
DIAGNOSIS
STEP 1. Check the weatherstrip for holding
condition.
Q: Is the weatherstrip holding firmly?
YES :
Go to Step 2.
NO : Adjust fit of door (Refer to P.42-32). Then
go to Step 5.
STEP 2. Check the weatherstrip for installation
condition.
Q: Is the weatherstrip installed properly?
YES :
Go to Step 3.
NO : Repair or replace the weatherstrip. Then go
to Step 5.

DOOR
BODY42-32
GLASS SLIDING MECHANISM CHECK AND
ADJUSTMENT
M1429000900109
If the window glass automatically starts moving downwards at
the wrong time while it is being raised, carry out the following
adjustment or replacement procedures.
1. Remove the door trim assembly (Refer to GROUP 52A,
Door trim P.52A-14).
2. Remove the waterproof film (Refer to P.42-52).
Insert a cushion or similar object to prevent damage to the
glass if it should fall.
3. Remove the window regulator assembly from the door
window glass, and then raise and lower the door window
glass by hand to check the operation force.
4. If the door window glass does not move up and down
smoothly, check or repair the following points:
Check the installation condition of the runchannel.
Repair any twisting in the door sash.
Check the installation condition of the lower sash.
NOTE: To align the lower sash, loosen the lower sash
mounting bolts, and move the lower sash along the oblong
mounting holes.
5. If repair or adjustment is not possible, replace the door
assembly.
POWER WINDOW TIMER FUNCTION CHECKM1429004300154
After the doors are closed and the ignition switch is turned to
the "LOCK" (OFF) position, the power windows should work
within 30 seconds. The timer expires if the front door is opened
during that 30 seconds. If it does not, carry out the timer trou-
bleshooting in GROUP 54B, SWS Diagnosis P.54B-57.

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.

BASIC BRAKE SYSTEM DIAGNOSIS
BASIC BRAKE SYSTEM35A-7
STEP 6. Check the master cylinder piston return spring for
damage and return port for clogging.
Refer to P.35A-28.
Q: Is there damage?
YES : Replace the part. Then go to Step 9.
NO : Go to Step 7.
STEP 7. Check port for clogging.
Q: Is the port clogged?
YES : Repair it. Then go to Step 9.
NO : Go to Step 8.
STEP 8. Check disc brake pistons for sticking.
Depress the brake pedal, then release. Confirm each wheel
spins freely.
Q: Does any wheel stick?
YES : Inspect that brake assembly. Then go to Step 9.
NO : Go to Step 9.
STEP 9. 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.
INSPECTION PROCEDURE 5: Scraping or Grinding Noise when Brakes are Applied
.
DIAGNOSIS
STEP 1. Check the front brakes, then rear brakes, for
metal-to-metal condition.
Q: Is any metal-to-metal contact evident?
YES : Repair or replace the components. Then go to Step 6.
NO : Go to Step 2.
STEP 2. Check for interference between the caliper and
wheel.
Q: Is there any interference?
YES : Repair or replace the part. Then go to Step 6.
NO : Go to Step 3.