2005 MITSUBISHI 380 check engine

ON-VEHICLE SERVICE
BASIC BRAKE SYSTEM35A-15
(2) With the engine stopped, step on the brake pedal several
times. Then step on the brake pedal and start the engine.
If the pedal moves downward slightly, the booster is in
good condition. If there is no change, the booster is
defective. Go to step 3.
(3) With the engine running, step on the brake pedal and
then stop the engine. Hold the pedal depressed for 30
seconds. If the pedal height does not change, the booster
is in good condition, if the pedal rises, the booster is
defective.
2. If the above three tests are okay, the booster is OK. If one of
the above three tests is not okay, the check valve, vacuum
hose, or booster is defective. Check the check valve (Refer
to P.35A-15), vacuum hose for leaks, high volume engine
vacuum applied to booster. Repair or replace as necessary.
If these are OK, replace booster and repeat this test starting
at Step 1.
CHECK VALVE OPERATION CHECKM1351009000376
The check valve should not be removed from the vacuum
hose.
1. Remove the vacuum hose. (Refer to P.35A-26).
If the check valve is defective, replace it as an assembly
together with the vacuum hose.
2. Check the operation of the check valve by using a vacuum
pump.
VACUUM PUMP
CONNECTIONCRITERIA
Connection at the brake
booster side (A)A negative pressure
(vacuum) is created and
held.
Connection at the intake
manifold side (B)A negative pressure
(vacuum) is not created.

ON-VEHICLE SERVICE
BASIC BRAKE SYSTEM35A-16
BLEEDINGM1351001400455
Use only brake fluid DOT 3 or DOT 4. Never mix the speci-
fied brake fluid with other fluid as it will influence the brak-
ing performance significantly.
.
MASTER CYLINDER BLEEDING
The master cylinder used has no check valve, so if bleeding is
carried out by the following procedure, bleeding of air from the
brake pipeline will become easier. (When brake fluid is not con-
tained in the master cylinder).
1. Fill the reserve tank with brake fluid.
2. Keep the brake pedal depressed.
3. Have another person cover the master cylinder outlet with a
finger.
4. With the outlet still closed, release the brake pedal.
5. Repeat steps 2
4 three or four times to fill the inside of the
master cylinder with brake fluid.
.
BRAKE LINE BLEEDING
Start the engine and bleed the air in the sequence shown in the
figure.

DISC BRAKE ASSEMBLY
BASIC BRAKE SYSTEM35A-31
INSTALLATION SERVICE POINT
.
>>A<< BRAKE DRAG FORCE CHECK
1. In order to measure the brake drag force, measure the hub
torque with the pads removed by the following procedure.
Use a spring scale to measure the hub torque in the forward
direction. Record hub torque with pads removed.
Do not let any oil, grease or other contamination get onto
the friction surfaces of the pads and brake discs.
2. After re-installing the caliper support to the knuckle, install
the pad clips and the pads to the caliper support.
3. Clean the piston and insert into cylinder with special tool
MB990520.
4. Be careful that the piston boot does not become caught,
when lowering the caliper assembly and installing the lock
pin bolt.
5. Check the brake drag force as follows.
(1) Start the engine and hold the brake pedal down for 5
seconds. [Pedal depression force: approximately 200 N
(45 pound)]
(2) Stop the engine.
(3) Turn the brake disc forward 10 times.

DISC BRAKE ASSEMBLY
BASIC BRAKE SYSTEM35A-32
(4) Use a spring scale to measure the hub torque with pads
installed in the same direction as earlier.
(5) Calculate the drag force of the disc brake [difference
between hub torque with pads installed and hub torque
with pads removed].
Standard value:
3.8L engine> 64 N (14 pounds) or less
54 N (12 pounds) or less
6. If the brake drag force exceeds the standard value,
disassemble and clean the piston. Check for corrosion or
worn piston seal, and check the sliding condition of the lock
pin and guide pin.
INSPECTIONM1351008100046.
BRAKE DISC CHECK
Disc wear (Refer to P.35A-19).
Disc run-out (Refer to P.35A-19).

GENERAL00-2
MAINTENANCE SERVICE . . . . . . . .00-37
1. FUEL SYSTEM (TANK, PIPE LINE AND
CONNECTION, AND FUEL TANK FILLER
TUBE CAP) (CHECK FOR LEAKS) . . . . . . 00-37
2. FUEL HOSES (CHECK CONDITION) . . 00-37
3. AIR CLEANER FILTER (REPLACE). . . . 00-37
4. EVAPORATIVE EMISSION SYSTEM
(EXCEPT EVAPORATIVE EMISSION
CANISTER) (CHECK FOR CLOGGING) . . 00-37
5. SPARK PLUGS (REPLACE). . . . . . . . . . 00-38
7. TIMING BELT (REPLACE) . . . . . . . . . . . 00-38
8. DRIVE BELTS (FOR ALTERNATOR, POWER
STEERING PUMP AND AIR CONDITIONING)
(CHECK) . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-39
9. EXHAUST SYSTEM (CONNECTIONS
PORTION OF MUFFLER, MUFFLER PIPES
AND CONVERTER HEAT SHIELDS) (CHECK
AND SERVICE AS REQUIRED) . . . . . . . . . 00-44
10. ENGINE OIL (CHANGE) . . . . . . . . . . . . 00-4411. ENGINE OIL FILTER (REPLACE) . . . . 00-44
12. TRANSMISSION FLUID . . . . . . . . . . . . 00-45
13. ENGINE COOLANT (CHANGE) . . . . . . 00-47
14. COOLANT HOSES (RADIATOR HOSE,
HEATER HOSE) (INSPECT). . . . . . . . . . . . 00-49
15. DISC BRAKE PADS, ROTORS
(INSPECT FOR WEAR) . . . . . . . . . . . . . . . 00-49
16. BRAKE HOSES (CHECK FOR
DETERIORATION OR LEAKS) . . . . . . . . . . 00-49
17. BALL JOINT AND STEERING LINKAGE
SEALS (INSPECT FOR GREASE LEAKS
AND DAMAGE) . . . . . . . . . . . . . . . . . . . . . . 00-50
18. DRIVE SHAFT BOOTS (INSPECT FOR
GREASE LEAKS AND DAMAGE) . . . . . . . . 00-50
19. SUSPENSION SYSTEM (INSPECT FOR
LOOSENESS AND DAMAGE) . . . . . . . . . . 00-51
20. SRS AIR BAG (INSPECT FOR SRS
SYSTEM). . . . . . . . . . . . . . . . . . . . . . . . . . . 00-51
21. TYRES (ROTATE). . . . . . . . . . . . . . . . . 00-58

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
GENERAL00-7
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE
POINTS
TROUBLESHOOTING CONTENTSM1001013300062
During diagnosis, a DTC code associated with
other system may be set when the ignition
switch is turned on with connector(s) discon-
nected. On completion, confirm all systems
for DTC code(s). If DTC code(s) are set, erase
them all.
When the DIAGNOSTIC TOOL (MUT-III)
detects a diagnostic trouble code, its display
informs users whether a mechanical problem
currently exists (“current trouble”) or whether
it existed before but normal operation has
been restored (“past trouble”). However, if an
MPI, TPMS or SRS airbag-related DTC is set,
“Active DTC/Stored DTC” is not displayed. In
this case, follow the diagnosis procedure for
current trouble.
If a trouble, detected in a CAN communica-
tion-capable system, can be reproduced,
diagnose the CAN bus lines (Refer to GROUP
54C, Can Bus Line Diagnostics Chart
P.54C-15 or P.54C-15).
Troubleshooting of electronic control systems for
which the MUT -III can be used follows the basic out-
line described below. Even in systems for which the
MUT-III cannot be used, part of these systems still
follow this outline.
1. STANDARD FLOW OF DIAGNOSTIC
TROUBLESHOOTING
Troubleshooting strategy is shown in each group.
2. SYSTEM OPERATION AND SYMPTOM
VERIFICATION TESTS
If verification of the symptom(s) is difficult, proce-
dures for checking operation and verifying symptoms
are shown.
3. DIAGNOSTIC FUNCTION
The following trouble code diagnoses are shown.
How to read diagnostic trouble codes
How to erase diagnostic trouble codes
Input inspection service points
4. DIAGNOSTIC TROUBLE CODE CHART
If the MUT-III displays a diagnostic trouble code, find
the applicable inspection procedure according to this
chart.
5. SYMPTOM CHART
If there are symptoms, even though the MUT-III
shows that no DTCs are set, inspection procedures
for each symptom will be found by using this chart.
6. DIAGNOSTIC TROUBLE CODE
PROCEDURES
Indicates the inspection procedures corresponding to
each diagnostic trouble code. (Refer to P.00-9).
7. SYMPTOM PROCEDURES
Indicates the inspection procedures corresponding to
each symptom listed in the Symptom Chart (Refer to
P.00-9).
8. SERVICE DATA REFERENCE TABLE
Inspection items and normal judgment values have
been provided in this chart as reference information.
9. CHECK AT ECU TERMINALS
Terminal numbers for the ECU connectors, inspec-
tion items, and standard values have been provided
in this chart as reference information.
.
TERMINAL VOLTAGE CHECKS
1. Use correct tool to check each pin location on the
ENGINE-ECU Check harnes MB992044 and
measure with voltmeter.
Short-circuiting the positive (+) test probe
between a connector terminal and ground could
damage the vehicle wiring, the sensor, the ECU,
or all three. Use care to prevent this!
2. Insert the correct terminal tool into each of the
ENGINE-ECU check harness connector
terminals, and measure the voltage while referring
to the check chart.
NOTE: Measure voltage with the ECU connectors
connected.
You may find it convenient to pull out the ECU to
make it easier to connect the ENGINE-ECU check
harness.

PRECAUTIONS BEFORE SERVICE
GENERAL00-22
ENGINE MODEL STAMPING
The engine model is stamped on the cylinder block.
The engine model number is as shown as follow.
The engine serial number is stamped near the engine model
number.
PRECAUTIONS BEFORE SERVICE
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)M1001011600056
1. Items to review when servicing SRS:
(1) Be sure to read GROUP 52B, Supplemental
Restraint System (SRS). For safe operation,
please follow the directions and heed all
warnings.
(2) Wait at least 60 seconds after disconnecting
the battery cable before doing any further
work. The SRS system is designed to retain
enough voltage to deploy the air bag even
after the battery has been disconnected.
Serious injury may result from unintended air
bag deployment if work is done on the SRS
system immediately after the battery cable is
disconnected.
(3) Warning labels must be heeded when
servicing or handling SRS components.
Warning labels can be found in the following
locations.
Front impact sensor
Hood
Sun visor
Instrument panel (passenger ’s side)
SRS-ECU
Steering wheel
Clock spring
Air bag module (Driver's or front
passenger's)
Side-airbag module (Driver's side or front
passenger's side)
Side impact sensor
Seat belt pre-tensioner
(4) Always use the designated special tools and
test equipment.(5) Store components removed from the SRS in a
clean and dry place. The air bag module
should be stored on a flat surface and placed
so that the pad surface is facing upward.
(6) Never attempt to disassemble or repair the
SRS components (SRS-ECU, air bag module
and clock spring). If there is a defect, replace
the defective part.
(7) Whenever you finish servicing the SRS, check
the SRS warning light operation to make sure
that the system functions properly.
(8) Be sure to deploy the air bag before disposing
of the air bag module or disposing of a vehicle
equipped with an air bag (Refer to GROUP
52B, Air Bag Module Disposal Procedures
P.52B-254).
2. Observe the following when carrying out
operations on places where SRS components are
installed, including operations not directly related
to the SRS air bag.
(1) When removing or installing parts, do not allow
any impact or shock to occur to the SRS
components.
(2) If heat damage may occur during paint work,
remove the SRS-ECU, the air bag module,
clock spring, the front impact sensor, the side
impact sensor, and the seat belt pre-tensioner.
a.SRS-ECU, air bag module, clock spring,
front impact sensor, the side impact sensor:
93
C (200F) or more
b.Seat belt pre-tensioner: 90
C (194F) or
more ENGINE MODEL ENGINE DISPLACEMENT
6G75 3828cc

PRECAUTIONS BEFORE SERVICE
GENERAL00-23
HOW TO PERFORM VEHICLE IDENTIFICATION
NUMBER (VIN) WRITING
M1001011400063
The Vehicle Identification Number (VIN) is stored in the ECU by
the vehicle manufacture. If the VIN to be stored in the ECU is
eliminated fraudulently, the Malfunction Indicator Lamp (Check
Engine Lamp) illuminates and Diagnostic Trouble Code (DTC)
No.P0630 (VIN malfunction) is shown. When the ECU is
replaced, and entry of the VIN necessary due to DTC No.
P0630 (VIN malfunction). Enter the VIN in accordance with the
procedure as follows:
.
WRITING PROCEDURE
Required Special Tools:
Diagnostic Tool (MUT-III)
MB991824: V.C.I.
MB991827: MUT-III USB Cable
MB991910: MUT-III Main Harness A (BLUE)
To prevent damage to DIAGNOSTIC TOOL (MUT-III), always
turn the ignition switch to the "LOCK" (OFF) position
before connecting or disconnecting.
1. Connect Diagnostic Tool to the data link connector.
2. Turn the ignition switch to the "ON" position.
3. Confirm DTC No.P0630 (EEPROM malfunction) is not
shown.
NOTE: When DTC No. P0630 (EEPROM malfunction) is
shown, the VIN cannot be stored even if entered. Therefore,
the troubleshooting is performed when this DTC is shown.
4. Select "Coding" form the menu screen.
5. Select "VIN writing" form the menu screen.
6. Enter the VIN.
7. After entry of the VIN, turn the ignition switch to the "LOCK"
(OFF) position. After ten seconds or more passed, turn to
the "ON" position again.
8. Confirm DTC No.P0630 (VIN malfunction) is not shown.
NOTE: When DTC No.P0630 (VIN malfunction) is shown,
enter the VIN again because that would be not appropriate.