power steering MITSUBISHI 380 2005 Workshop Manual

SWS DIAGNOSIS
SIMPLIFIED WIRING SYSTEM (SWS)54B-14
6. Remove the steering column cover.
7. Remove the steering column switch connector.
8. Connect special tool MB991812 to the column switch
connector.
9. Connect special tool MB991812 to special tool MB991806.
10.Connect special tool MB991806 to special tool MB991824.
11.Turn the power switch of special tool MB991824 to the "ON"
position.
NOTE: When special tool MB991824 is energised, special
tool MB991824 indicator lamp will be illuminated in a green
color.
12.Start the MUT-III system on the personal computer.

ENGINE AND TRANSMISSION
CONFIGURATION DIAGRAMS80-7
B-19 (34) A/T-ECU
B-20 (60) ENGINE-ECU
B-21 (94) ENGINE-ECU
B-22 (26) A/T-ECU
B-24 (4-GR) LEFT BANK HEATED OXYGEN
SENSOR (REAR)
B-25 (4-B) LEFT BANK HEATED OXYGEN
SENSOR (FRONT)
B-26 (2-GR) INJECTOR 6B-27 (2-GR) INJECTOR 4
B-28 (1-B) A/C COMPRESSOR ASSEMBLY
B-29 (1-B) ENGINE OIL PRESSURE SWITCH
B-30 (2-GR) INJECTOR 2
B-31 (1-B) POWER STEERING PRESSURE
SWITCH
B-32 (10-B) CONTROL WIRING HARNESS AND
INJECTOR WIRING HARNESS
COMBINATION

ON-VEHICLE SERVICE
HEATER, AIR CONDITIONING AND VENTILATION55-146
Sharper bends will reduce the flow of refrigerant. The flexible
hose lines should be routed so that they are at least 80 mm
(3.1 inches) from the exhaust manifold. It is good practice to
inspect all flexible hose lines at least once a year to make sure
they are in good condition and properly routed.
On standard plumbing fittings with O-rings, these O-rings are
not reusable.
AIR CONDITIONING NOISE TEST
You must first know the conditions when the noise occurs.
These conditions are: weather, vehicle speed, in gear or neu-
tral, engine temperature or any other special conditions.
Noises that develop during A/C operation can often be mislead-
ing. For example: what sounds like a failed front bearing or
connecting rod, may be caused by loose bolts, nuts, mounting
brackets, or a loose clutch assembly. Verify accessory drive
belt tension (power steering or generator).
Improper accessory drive belt tension can cause a misleading
noise when the compressor is engaged and little or no noise
when the compressor is disengaged.
Drive belts are speed-sensitive. That is, at different engine
speeds, and depending upon belt tension, belts can develop
unusual noises that are often mistaken for mechanical prob-
lems within the compressor.
Normal air conditioning operation will generate some level of
operational noise. To judge what is normal and abnormal,
requires an understanding of the air conditioning system. This
test is to detail the most common noise complaints and the
repair methods.
VEHICLE CONDITION
1. Ensure the system is not over or under charged.(Refer to
P.55-142).
2. Tighten all compressor mounting bolts, clutch mounting
bolts and compressor drive belt.
3. Inspect layout of the system is correct, ie no interference
between hoses and all retaining clamps are in place.

CONDENSER AND CONDENSER FAN
HEATER, AIR CONDITIONING AND VENTILATION55-167
CONDENSER AND CONDENSER FAN
REMOVAL AND INSTALLATIONM1552006700414
Pre-removal and Post-installation Operation
Refrigerant Draining and Refilling (Refer to P.55-142).
Air Duct Removal and Installation (Refer to GROUP 15,
Air Cleaner P.15-4).
Radiator Grilles Removal and Installation (Refer to
GROUP 51, Radiator Grilles P.51-6).
Front End Structure Bar Removal and Installation (Refer
to GROUP 14, Radiator P.14-32).
Cooler tube removal (Refer to GROUP 37, Power steering
P.37-45).
CONDENSER REMOVAL STEPS
<>1. FLEXIBLE DISCHARGE HOSE
CONNECTION
<>2. LIQUID PIPE A CONNECTION3. O-RING
>>B<<4. CONDENSER ASSEMBLY
5. RECEIVER CONDENSER REMOVAL STEPS

OTHER DEVICES
COMPONENT LOCATIONS70-18
OTHER DEVICESM1701005600302
NAME SYMBOL NAME SYMBOL
Power steering pressure switch A

THERMOSTAT
ENGINE COOLING14-35
THERMOSTAT
REMOVAL AND INSTALLATIONM1141002400475
Pre-removal and Post-installation Operation
Engine Coolant Draining and Refilling (Refer to 27).
Engine Cover Removal and Installation (Refer to GROUP
11C, Engine Assembly 11A-14).
Engine Control Unit (ECU) Removal and Installation
(Refer to GROUP 00, General 00-7).
Air Cleaner Removal and Installation (Refer to GROUP
15, Air Cleaner 4).
Strut Tower Bar Removal and Installation (Refer to
GROUP 42, Strut Tower Bar 12).
Battery and Battery Tray Removal and Installation
REMOVAL STEPS
1. LEFT BANK HEATED OXYGEN
SENSOR (REAR) CONNECTOR
2. LEFT BANK HEATED OXYGEN
SENSOR (FRONT) CONNECTOR
3. RIGHT BANK HEATED OXYGEN
SENSOR (REAR) CONNECTOR
4. RIGHT BANK HEATED OXYGEN
SENSOR (FRONT) CONNECTOR
5. THROTTLE BODY ASSEMBLY
CONNECTOR
6. EVAPORATIVE EMISSION
PURGE SOLENOID CONNECTOR7. MANIFOLD ABSOLUTE
PRESSURE SENSOR
CONNECTOR
8. POWER STEERING PRESSURE
SWITCH CONNECTOR
9. CONTROL WIRING HARNESS
AND WIRING HARNESS
COMBINATION CONNECTOR
10. KNOCK SENSOR CONNECTOR
11. CRANKSHAFT POSITION
SENSOR CONNECTOR
13. INJECTOR CONNECTORREMOVAL STEPS (Continued)

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)

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)

SPECIFICATIONS
INTAKE AND EXHAUST15-18
SERVICE SPECIFICATIONM1151000300462
SEALANTSM1151000500187
Intake manifold plenum
Evaporative emission purge solenoid bolt 9.0
1.0 Nm (80 9 in-lb)
Harness bracket bolt 11
1 Nm (98 8 in-lb)
Intake manifold plenum bolt 18
2 Nm (13 2 ft-lb)
Intake manifold plenum stay bolt M8 18
2 Nm (13 2 ft-lb)
M10 36
6 Nm (27 4 ft-lb)
Manifold absolute pressure sensor bolt 5.0
1.0 Nm (44 9 in-lb)
Power steering pressure hose clamp nut 12
2 Nm (102 22 in-lb)
Power steering pressure hose clamp bracket bolt 12
2 Nm (102 22 in-lb)
Power steering oil pump bracket connecting bolt 41
8 Nm (30 6 ft-lb) ITEMSPECIFICATION
ITEM STANDARD VALUE LIMIT
Manifold distortion of the installation surface mm (in) 0.15 (0.006) or less 0.20 (0.008)
ITEM SPECIFIED SEALANT
Thermostat case assembly 3M
AAD Part No.8672, 3M AAD Part No.8679/8678 or
equivalent
Thermostat case assembly bolt 3M
AAD Part No. 8730, 8731 or equivalent

CHARGING SYSTEM
ENGINE ELECTRICAL16-3
CHARGING SYSTEM DIAGNOSISM1161000700427
TROUBLESHOOTING HINTS
Alternator malfunction light dose not go on when the ignition
switch is turned to ON, before the engine starts.
Check the bulb.
Alternator malfunction light dose not switch off after the engine
starts.
Check the IC voltage regulator inside the
alternatoralternator.
Discharged or overcharged battery.
Check the IC voltage regulator inside the alternator.
The alternator malfunction light illuminates dimly.
Check the diode (inside the combination meter) for a
short-circuit.
TROUBLESHOOTING GUIDE
The charging system troubleshooting guide is shown in the fol-
lowing steps.
STEP 1.
Q: Is the battery in good condition? (Refer to GROUP 54A,
Chassis Electrical
Battery On-vehicle Service
Battery Check P.54A-5.)
YES : Go to Step 2.
NO : Charge or replace the battery.
STEP 2.
Q: Is the alternator drive belt in good condition? (Refer to
GROUP 00, General
Maintenance Service Drive Belts
(For Alternator, Power Steering Pump and Air
Conditioning) (Check) P.00-39.)
YES : Go to Step 3.
NO : Adjust the belt tension or replace the belt.
STEP 3.
Q: Does the alternator malfunction light come on when the
ignition switch is turned on?
YES : Go to Step 4.
NO :
Check the ignition switch. (Refer to GROUP 54A,
Chassis Electrical
Ignition Switch Ignition
Switch
Inspection P.54A-44.)
Check for burnt-out alternator malfunction light.
Check the alternator. (Refer to Charging System
Alternator Assembly
Inspection P.16-17.)
Check the alternator malfunction light-related
circuits.