tow bar MITSUBISHI 380 2005 Workshop Manual

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 EXHAUST15-5
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).

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)

42-1
GROUP 42
BODY
CONTENTS
HOOD . . . . . . . . . . . . . . . . . . . . .
42-4
BODY DIAGNOSIS . . . . . . . . . . . .
42-4
INTRODUCTION TO HOOD DIAGNOSIS42-4
HOOD DIAGNOSTIC TROUBLESHOOTING
STRATEGY . . . . . . . . . . . . . . . . . . . . . . 42-4
SYMPTOM CHART . . . . . . . . . . . . . . . . 42-4
SYMPTOM PROCEDURES . . . . . . . . . 42-4
ON-VEHICLE SERVICE. . . . . . . . .42-6
ADJUSTMENT OF CLEARANCE
AROUND HOOD . . . . . . . . . . . . . . . . . . 42-6
ALIGNMENT OF HOOD LATCH AND
STRIKER . . . . . . . . . . . . . . . . . . . . . . . . 42-6
ADJUSTMENT OF HOOD HEIGHT . . . 42-7
HOOD . . . . . . . . . . . . . . . . . . . . . . .42-8
REMOVAL AND INSTALLATION . . . . . 42-8
FENDER . . . . . . . . . . . . . . . . . . .42-10
REMOVAL AND INSTALLATION .
42-10
FUEL FILLER LID . . . . . . . . . . .42-11
REMOVAL AND INSTALLATION .
42-11
STRUT TOWER BAR . . . . . . . . 42-12
REMOVAL AND INSTALLATION .
42-12
WINDOW GLASS . . . . . . . . . . . 42-12
GENERAL . . . . . . . . . . . . . . . . . . . .
42-12
WINDOW GLASS DIAGNOSIS . . .42-14
INTRODUCTION TO WINDOW GLASS
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 42-14
WINDOW GLASS DIAGNOSTIC
TROUBLESHOOTING STRATEGY . . . . 42-14
WINDOW GLASS DIAGNOSTIC TROUBLE
SYMPTOM CHART . . . . . . . . . . . . . . . . 42-14
SYMPTOM PROCEDURES . . . . . . . . . . 42-14
SPECIAL TOOL . . . . . . . . . . . . . . .42-14
WINDSHIELD . . . . . . . . . . . . . . . . .42-15
REMOVAL AND INSTALLATION . . . . . . 42-15
REAR WINDOW GLASS . . . . . . . .42-20
REMOVAL AND INSTALLATION . . . . . . 42-20
Continued on next page

STRUT TOWER BAR
BODY42-12
STRUT TOWER BAR
REMOVAL AND INSTALLATION (Where fitted)M1421005600109
WINDOW GLASS
GENERALM1422000100384
The windshield and rear window glass are attached
by an urethane-base adhesive to the window frame.
This adhesive provides improved glass holding and
sealing, and also gives body openings a greater
structural strength.
ITEMS
REMOVAL STEPS
1. STRUT TOWER BAR
2. STRUT TOWER BAR BRACKET
ITEM APPLICATION QUANTITY
Wire (diameter
length) For cutting adhesive Five pieces of wire 0.6 mm 1 m
(0.02 in
3.3 ft)
Glass adhesive knife For cutting adhesive One
Sealant gun For adhesive application One
Wiping shop towels - As required
Sealer For prevention of water and wind
leaks after adhesive applicationAs required
3M AAD
Part No. 8906 or
equivalentFor cleaning As required
Glass holder MB990480 For securing of window glass Two

DOOR
BODY42-30
ON-VEHICLE SERVICE
DOOR FIT ADJUSTMENTM1423001100380
Required Special Tools:
MB990211: Slide Hammer
MB990243: Body Puller
MB990900 or MB991164: Door adjusting Wrench
MB990939: Brass Bar
Attach protection tape to the fender and door edges
where the hinge is installed.
Do not rotate special tool MB991164 with a torque of
over 98 N
m (72 ft-lb).
1. Use special tool MB990900 or MB991164 to loosen the
hinge mounting bolts on the body side, and then adjust the
clearance around the door so that it is uniform on all sides.
2. If a door is not flush with its surrounding panels, loosen the
door-side door hinge mounting bolts and adjust the door as
necessary.
NOTE:
If the door hinge mounting bolt washers are welded,
grind off the welding according to the procedure below
beforehand.
.
1. Remove the door hinge. (Refer P.42-37.)
2. Remove the plastic cover from bolt head. (Refer
P.42-37.)
3. Use a chisel or grinder to release the door hinge mount-
ing bolt washer, which is welded to the door hinge.
4. On completion, paint the affected area with touch-up
paint to prevent corrosion.
5. Install the door hinge. (Refer P.42-37.)
3. If the door is stiff to lock and unlock:
(1) Adjustment by using the striker (vertically or toward the
inside of the vehicle)
Install an temporary bolts instead of the striker mounting
bolt, and use special tool MB990939 and a hammer to
tap the bolt in the desired direction.

SPECIFICATIONS
BODY42-86
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONSM1421005300216
ITEM SPECIFICATION
Hood
Hood hinge bolt (body side) 12
2 Nm (102 22 in-lb)
Hood hinge bolt (hood side) 12
2 Nm (102 22 in-lb)
Hood hinge nut (body side) 12
2 Nm (102 22 in-lb)
Hood latch bolt 9.0
2.0 Nm (80 17 in-lb)
Strut tower bar
Strut tower bar nut 12
2 Nm (102 22 in-lb)
Strut tower bar bracket nut 48
7 Nm (36 5 ft-lb)
Door
Door check bolt (body side) 9.0
2.0 Nm (80 17 in-lb)
Door check bolt (door side) 5.0
1.0 Nm (44 9 in-lb)
Door hinge bolt (body side) 27
5 Nm (20 4 ft-lb)
Door hinge bolt (door side) 21
4 Nm (16 2 ft-lb)
Door outside handle bolt 5.0
1.0 Nm (44 9 in-lb)
Door latch assembly screw 5.9
1.0 Nm (52 9 in-lb)
Door switch screw 3.9
1.0 Nm (35 8 in-lb)
Striker screw 24
3 Nm (18 2 ft-lb)
Trunk lid
Trunk lid hinge bolt (body side) 13
2 Nm ( 111 22 in-lb)
Trunk lid hinge bolt (trunk lid side) 13
2 Nm ( 111 22 in-lb)
Trunk lid hinge nut (trunk lid side) 13
2 Nm ( 111 22 in-lb)
Trunk lid latch bolt 9.0
2.0 Nm (80 17 in-lb)
Trunk lid striker bolt 5.0
1.0 Nm (44 9 in-lb)
Sunroof
Roof lid glass screw 4.0
0.5 Nm (36 4 in-lb)
Sunroof drip plate screw 2.0 N
m (18 in-lb)
Sunroof housing screw 2.0 N
m (18 in-lb)
Sunroof motor bolt 5.4 N
m (48 in-lb)
Loose panel
Cowl top cover outer bolt 11
2 Nm (98 17 in-lb)
Front end structure bar bolt 22
4 Nm (16 2 ft-lb)
12
2 Nm (102 22 in-lb)
11
2 Nm (98 17 in-lb)
Front floor backbone brace bolt 22
4 Nm (16 2 ft-lb)
Upper frame to front pillar brace bolt 22
4 Nm (16 2 ft-lb)

MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER
BASIC BRAKE SYSTEM35A-26
MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER
REMOVAL AND INSTALLATIONM1351003700407
Required Special Tool:
MB991568: Push Rod Adjusting Socket
Pre-removal Operation
Strut Tower Bar Removal (Refer to GROUP 42, Strut
To w e r B a r P.42-12).
Battery Removal
Brake Fluid DrainingPost-installation Operation
Brake Fluid Supplying and Air Bleeding (Refer to
P.35A-16).
Brake Pedal Adjustment (Refer to P.35A-13).
Battery Installation
Strut Tower Bar Installation (Refer to GROUP 42, Strut
Tower Bar P.42-12).
BRAKE MASTER CYLINDER
ASSEMBLY REMOVAL STEPS
1. BRAKE FLUID LEVEL INDICATOR
SWITCH CONNECTOR
2. BRAKE TUBE CONNECTION
5. BRAKE MASTER CYLINDER
ASSEMBLY
6. SPRING PIN
7. BRAKE FLUID RESERVOIR
ASSEMBLY
8. MASTER CYLINDER FLUID
RESERVOIR SEAL
9. BRAKE FLUID LEVEL INDICATOR
SWITCH
10. BRAKE FLUID RESERVOIR CAP
BRAKE BOOSTER VACUUM
HOSE REMOVAL STEP
>>A<<11. BRAKE BOOSTER VACUUM
HOSE BRAKE BOOSTER ASSEMBLY
REMOVAL STEPS
1. BRAKE FLUID LEVEL INDICATOR
SWITCH CONNECTOR
2. BRAKE TUBE CONNECTION
5. BRAKE MASTER CYLINDER
ASSEMBLY
>>B< AMOUNT CHECK AND
ADJUSTMENT
>>A<<11. BRAKE BOOSTER VACUUM
HOSE
12. BRAKE BOOSTER PIN
13. BRAKE BOOSTER PIN
ASSEMBLY
14. BRAKE BOOSTER NUT
15. BRAKE BOOSTER ASSEMBLY
16. BRAKE BOOSTER BODY SEAL