belt MITSUBISHI 380 2005 Service Manual

COMPRESSOR ASSEMBLY AND DRIVE BELT
HEATER, AIR CONDITIONING AND VENTILATION55-166
INSPECTIONM1552014301083
COMPRESSOR AIR CONDITIONING
COMPRESSOR CLUTCH OPERATION CHECK
Connect the compressor connector terminal to the battery posi-
tive (+) terminal and ground the battery’s negative (-) terminal
to the compressor unit. At that time, the air conditioning com-
pressor clutch should make a definite operating sound.
.
AIR GAP ADJUSTMENT
Check whether or not the air gap of the clutch is within the stan-
dard value.
Standard value:
0.35
0.60mm
NOTE: If there is a deviation of the air gap from the standard
value, assess the operation of the clutch and replace the com-
pressor assembly as required.

HOW TO DIAGNOSE
GENERAL 00E-9
CABLES AND WIRES CHECKM1001005100041
1. Check connections for looseness, rust, and stains.
2. Check terminals and wires for corrosion.
3. Check terminals and wires for open circuit or impending
open circuit.
4. Check wire insulation and coating for damage, cracks, and
wear.
5. Check conductive parts of terminals for contact with other
metallic parts (vehicle body and other parts).
6. Check grounding parts to verify that there is complete
continuity between attaching bolt(s) and vehicle body.
7. Check for incorrect wiring.
8. Check that harnesses are secured to prevent contact with
sharp edges and corners or hot parts (exhaust manifold,
pipe, etc.).
9. Check that harnesses are secured firmly to provide enough
clearance from the fan pulley, fan belt, and other rotating or
moving parts.
10.Check that the harnesses between fixed parts (such as the
vehicle body) and vibrating parts (such as the engine) are
long enough to allow for vibration and movement.
BATTERY HANDLINGM1001005200048
Battery posts, terminals and related accessories con-
tain lead and lead compounds. WASH HANDS AFTER
HANDLING.
When checking or servicing does not require power from the
vehicle battery, be sure to disconnect the cable from the battery
(
) terminal. This will prevent problems that could be caused by
a short circuit. Disconnect the (
) battery terminal first and
reconnect it last.
GENERAL ELECTRICAL SYSTEM CHECKM1001005300045
A circuit consists of the power supply, switch, relay, load,
ground, etc. There are various methods to check a circuit
including an overall check, voltage check, short-circuit check,
and continuity check. Each of the methods briefly described
below applies only to circuits similar to the illustration.

GENERAL DESCRIPTION
ENGINE COOLING14-2
GENERAL DESCRIPTIONM1141000100401
The cooling system is designed to keep every
part of the engine at appropriate temperature in
whatever condition the engine may be operated.
The cooling method is of the water-cooled, pres-
sure forced circulation type in which the water
pump pressurizes coolant and circulates it
throughout the engine. If the coolant temperature exceeds the prescribed temperature, the thermo-
stat opens to circulate the coolant through the
radiator as well so that the heat absorbed by the
coolant may be radiated into the air. The water
pump is of the centrifugal type and is driven by
the drive belt from the crankshaft. The radiator is
the corrugated fin, down flow type.
SPECIAL TOOLM1141000600279
ENGINE COOLING DIAGNOSIS
INTRODUCTIONM1141005300347
The system cools the engine so that it does not over-
heat and maintains the engine at an optimum tem-
perature. The system components are the radiator,
water pump, thermostat, condenser and fan assem-
blies. Possible faults include low coolant, contamina-
tion, belt loosening and component damage.
TROUBLESHOOTING STRATEGYM1141005200340
Use these steps to plan your diagnostic strategy. If
you follow them carefully, you will be sure to find
most of the engine cooling faults.
1. Gather information from the customer.2. Verify that the condition described by the
customer exists.
3. Find and repair the malfunction by following the
SYMPTOM CHART.
4. Verify that the malfunction is eliminated. TOOL TOOL NUMBER AND
NAMESUPERSESSION APPLICATION
MB991871
LLC changerGeneral service tool Coolant refilling

ENGINE COOLING DIAGNOSIS
ENGINE COOLING14-4
INSPECTION PROCEDURE 2: Engine Overheating
DIAGNOSIS
STEP 1. Remove the radiator cap and check for coolant
contamination.
Q: Is the coolant contaminated with rust and oil?
YES : Replace it. Refer to P.14-27.
NO : There is no action to be taken. Go to Step 2.
STEP 2. Check the radiator cap valve opening pressure.
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 gauge indicator stops
moving.
Minimum limit: 83 kPa (12 psi)
Standard value: 93
123 kPa (14 18 psi)
Q: Does the reading remain at or above the minimum limit?
YES : Go to Step 3.
NO : Replace the radiator cap. Then go to Step 5.
STEP 3. Check thermostat operation.
Refer to 38.
Q: Does the thermostat operate correctly?
YES : Go to Step 4.
NO : Replace the thermostat, then go to Step 5.
STEP 4. Check the drive belt for slippage or damage.
Refer to GROUP 00, Maintenance Service
Drive Belts
(Check Condition). <3.8L Engine>39 .
Q: Is the drive belt loose or damaged?
YES : Adjust or replace the drive belt, then go to Step 5.
NO : There is no action to be taken.
STEP 5. Retest the system.
Check the engine coolant temperature.
Q: Is the engine coolant temperature abnormally high?
YES : Return to Step 2.
NO : The procedure is complete.

WATE R P U M P
ENGINE COOLING14-39
WAT E R P U M P
REMOVAL AND INSTALLATIONM1141002700498
INSTALLATION SERVICE POINT
.
>>A<< O-RING INSTALLATION
Do not let the O-ring get contaminated with grease or
engine oil.
Fit the O-ring into the groove of the water pipe ends, and apply
water or coolant to the circumference of the O-ring and the pipe
bores to insert the pipe assembly.
Pre-removal and Post-installation Operation
Engine Coolant Draining and Refilling (Refer to 27).
Timing Belt Removal and Installation (Refer to GROUP
11C, Timing Belt 11A-46).
Crankshaft Position Sensor Removal and Installation
(Refer to GROUP 16, Crankshaft Position Sensor 35).
REMOVAL STEPS
1. WATER PUMP BRACKET
2. WATER PUMP3. WATER PUMP GASKET
>>A<<4. 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)

SPECIFICATIONS
INTAKE AND EXHAUST15-16
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONSM1151006800506
ITEMSPECIFICATION
Air cleaner
Air cleaner bolt 8.8
1.0 Nm (78 9 in-lb)
Air cleaner bracket bolt and nut 12
2 Nm (102 22 in-lb)
Air cleaner resonator bolt 8.8
1.0 Nm (78 9 in-lb)
Air intake hose clamp bolt 4.0
0.9 Nm (35 8 in-lb)
Airflow sensor nut 8.0
1.0 Nm
Exhaust manifold
Exhaust manifold nut 44
5 Nm (33 3 ft-lb)
Front exhaust pipe bolt 49
9 Nm (37 6 ft-lb)
Exhaust manifold stay, left A bolt M8 19
3 Nm (14 2 ft-lb)
Exhaust manifold stay, left B bolt M10 44
8 Nm (33 5 ft-lb)
Heat protector bolt 14
1 Nm (120 13 in-lb)
Heated oxygen sensor 44
5 Nm (33 3 ft-lb)
Exhaust manifold
Exhaust manifold nut 44
5 Nm (33 3 ft-lb)
Exhaust manifold stay, right A bolt M12 75
10 Nm (55 7 ft-lb)
Exhaust manifold stay, right B bolt M10 44
5 Nm (33 3 ft-lb)
Heat protector bolt 14
1 Nm (120 13 in-lb)
Heated oxygen sensor 44
5 Nm (33 3 ft-lb)
Exhaust pipe and main muffler
Crossmember stay bolt 45
5 Nm (34 3 ft-lb)
Center exhaust pipe nut 49
9 Nm (37 6 ft-lb)
Front floor backbone brace bolt 22
4 Nm (16 3 ft-lb)
Front no.1 exhaust pipe bolt 35
4 Nm (26 3 ft-lb)
Front no.1 exhaust pipe to front no.2 exhaust pipe bolt 49
4 Nm (37 3 ft-lb)
Front no.1 exhaust pipe to right bank exhaust manifold nut 49
9 Nm (37 6 ft-lb)
Front no.1 exhaust pipe to left bank exhaust manifold bolt 49
9 Nm (37 6 ft-lb)
Hanger bolt 12
2 Nm (107 17 in-lb)
Main muffler bolt 49
4 Nm (37 3 ft-lb)
Heat protector bolt 14
1 Nm (120 13 in-lb)
Intake manifold
Control harness clamp bolt 11
1 Nm (98 8 in-lb)
Engine mounting stay bolt 36
6 Nm (27 4 ft-lb)
Fuel rail and injector bolt 12
1 Nm (102 13 in-lb)
Intake manifold bolt 22
1 Nm (16 1 ft-lb)
Timing belt front upper cover bolt M6 11
1 Nm (98 8 in-lb)
M8 14
1 Nm (120 13 in-lb)