MITSUBISHI 380 2005 Workshop Manual

HOW TO DIAGNOSE
GENERAL 00E-10
1. VOLTAGE CHECK
(1) Ground one lead wire of the test light. If a voltmeter is
used instead of the test light, ground the grounding side
lead wire.
(2) Connect the other lead wire of the test light to the power
side terminal of the switch connector. The test light
should come on or the voltmeter should indicate a
voltage.
(3) Then, connect the test light or voltmeter to the motor
connector. The test light should not come on, or the
voltmeter should indicate no voltage. When the switch is
turned ON in this state, the test light should come on, or
the voltmeter should indicate a voltage, with the motor
starting to run.
(4) The circuit illustrated here is normal. If there is any
problem, such as the motor failing to run, check voltages
beginning at the connector nearest to the motor until the
faulty part is identified.
2. SHORT-CIRCUIT CHECK
Because the fuse has blown, it is probable that there is a
short circuit. Follow the procedures below to narrow down
the short-circuit location.
STEP 1. Remove the blown fuse and connect the test light
across the fuse terminals (Circuit switch: OFF).
Q: Does the test light illuminate?
YES : Short-circuit exists between the fuse block and the
switch. Diagnose the harness between the fuse block
and the switch.
NO : Go to Step 2.

HOW TO DIAGNOSE
GENERAL 00E-11
STEP 2. Turn the switch ON and disconnect the
illumination light connector.
Q: Does the test light illuminate?
YES : Short-circuit exists between the switch and the
connector. Diagnose the harness between the switch
and the connector.
NO : Short-circuit exists between the connector and the
illumination light. Diagnose the harness between the
connector and the illumination light.

HOW TO DIAGNOSE
GENERAL 00E-12
3. CONTINUITY CHECK
(1) When the switch is in the "OFF" position and the contact
points of terminals 1 and 2 are connected, the
self-powered test light should illuminate or the ohmmeter
should read 0 ohm.
(2) When the switch is the "ON" position and the contact
points of terminals 3 and 4 are connected, the
self-powered test light should come on or the ohmmeter
should read 0 ohm.

11-1
GROUP 11
ENGINE
CONTENTS
ENGINE MECHANICAL <3.8L ENGINE> . . . . . . . . . . . . . . . . . .11A
ENGINE OVERHAUL <3.8L ENGINE> . . . . . . . . . . . . . . . . . . . .11B

NOTES

14-1
GROUP 14
ENGINE COOLING
CONTENTS
GENERAL DESCRIPTION. . . . . . . . .14-2
SPECIAL TOOL . . . . . . . . . . . . . . . . .14-2
ENGINE COOLING DIAGNOSIS . . . .14-2
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . 14-2
TROUBLESHOOTING STRATEGY . . . . . . 14-2
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 14-3
SYMPTOM PROCEDURES . . . . . . . . . . . . 14-3
ON-VEHICLE SERVICE . . . . . . . . . . .14-26
ENGINE COOLANT LEAK CHECK . . . . . . 14-26
RADIATOR CAP PRESSURE CHECK . . . . 14-27
ENGINE COOLANT REPLACEMENT . . . . 14-27
ENGINE COOLANT CONCENTRATION TEST14-29
FAN CONTROLLER CHECK . . . . . . . . . . . 14-29
FAN CONTROL RELAY CONTINUITY CHECK14-31
RADIATOR . . . . . . . . . . . . . . . . . . . . .14-32
REMOVAL AND INSTALLATION . . . . . . . . 14-32
THERMOSTAT . . . . . . . . . . . . . . . . . .14-35
REMOVAL AND INSTALLATION . . . . . . . . 14-35
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 14-38
WATER PUMP . . . . . . . . . . . . . . . . . .14-39
REMOVAL AND INSTALLATION . . . . . . . . 14-39
WATER HOSE AND WATER PIPE . .14-40
REMOVAL AND INSTALLATION . . . . . . . . 14-40
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 14-41
SPECIFICATIONS . . . . . . . . . . . . . . .14-42
FASTENER TIGHTENING
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . 14-42
SERVICE SPECIFICATION . . . . . . . . . . . . 14-43
CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . 14-43
SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . 14-43

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 COOLING14-3
SYMPTOM CHARTM1141005600393
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Coolant Leak
DIAGNOSIS
STEP 1. Check for coolant leaks.
When pressure testing the cooling system, slowly
release cooling system pressure to avoid being
burned by hot coolant.
Be sure to completely clean away any moisture from
the places checked.
When the tester is removed, be careful not to spill any
coolant.
When installing and removing the tester and when test-
ing, be careful not to deform the filler neck of the radia-
tor.
Check that the coolant level is up to the filler neck. Install a radi-
ator tester and apply 160 kPa (23 psi) pressure, and then check
for leakage from the radiator hose or connections.
Q: Is leakage present from the radiator hose or
connections?
YES : Repair or replace the appropriate part, then go to
St e p 2 .
NO : There is no action to be taken.
STEP 2. Retest the system.
Q: Is there still coolant leakage?
YES : Return to Step 1.
NO : The procedure is complete. SYMPTOM INSPECTION
PROCEDUREREFERENCE
PA G E
Coolant leak 1
14-3
Engine overheating 2
14-4
Radiator fan and condenser fan do not operate 3
14-4
Radiator fan and condenser fan do not change speed or stop 4
14-20
Radiator fan does not operate 5
14-25
Condenser fan does not operate 6
14-25

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.

ENGINE COOLING DIAGNOSIS
ENGINE COOLING14-5
INSPECTION PROCEDURE 3: Radiator Fan and Condenser Fan do not Operate
.
CIRCUIT OPERATION
The fan controller is powered from fusible link
No.2.
The engine-ECU uses input signals from the A/C
switch, the water temperature sensor unit and the
vehicle speed sensor or the output shaft
speed sensor to control the speed of the
radiator fan motor and the condenser fan motor.
The engine-ECU controls the fan controller to
activate the radiator fan motor and the condenser
fan motor.
.
TECHNICAL DESCRIPTION
The cause could be a malfunction of the fan con-
troller power supply or earth circuit.
If the communication line wiring harness between
the fan controller and the engine-ECU is
short-circuited to earth, the radiator fan motor
and the condenser fan motor will not rotate.
The cause could also be a malfunction of input
signal from the A/C switch, the water temperature
sensor unit and the vehicle speed sensor
or the output shaft speed sensor to the
engine-ECU.
The cause could also be a malfunction of the fan
controller or the engine-ECU.

.
TROUBLESHOOTING HINTS
Malfunction of fusible link No.2
Malfunction of fan control relay
Malfunction of cooling fan motor and fan control-
ler
Malfunction of engine-ECU.
Damaged wiring harness or connector
Refer to component locations GROUP-1
Refer to configuration diagrams GROUP-1
Refer to circuit diagrams GROUP-1