2005 MITSUBISHI 380 service

THERMOSTAT
ENGINE COOLING14-37
REMOVAL SERVICE POINT
.
<> RADIATOR LOWER HOSE DISCONNEC-
TION
Make mating marks on the radiator hose and the hose clamp.
Disconnect the radiator hose.
INSTALLATION SERVICE POINTS
.
>>A<< THERMOSTAT INSTALLATION
Make absolutely sure that no oil adheres to the rubber ring
of the thermostat. Also do not fold or scratch the rubber
ring during installation.
Install the thermostat so that the jiggle valve is facing straight
up. Be careful not to fold or scratch the rubber ring.
.
>>B<< RADIATOR LOWER HOSE CONNECTION
1. Insert each hose as far as the projection of the water inlet
fitting.
2. Align the mating marks on the radiator hose and hose
clamp, and then connect the radiator hose.

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)

WATER HOSE AND WATER PIPE
ENGINE COOLING14-40
WATER HOSE AND WATER PIPE
REMOVAL AND INSTALLATIONM1141003300493
REMOVAL SERVICE POINT
.
<> RADIATOR UPPER HOSE DISCONNEC-
TION
After making mating marks on the radiator hose and hose
clamp, disconnect the radiator hose.
Pre-removal and Post-installation Operation
Thermostat Removal and Installation (Refer to 35).
REMOVAL STEPS
<> >>C<<1. RADIATOR UPPER HOSE
CONNECTION
2. HEATER HOSE CONNECTION
5. THERMOSTAT HOUSING
6. GASKET>>B<<7. ENGINE COOLANT
TEMPERATURE SENSOR
8. WATER PUMP INLET PIPE
>>A<<9. O-RINGREMOVAL STEPS (Continued)

WATER HOSE AND WATER PIPE
ENGINE COOLING14-41
INSTALLATION SERVICE POINTS
.
>>A<< O-RING INSTALLATION
Do not allow engine oil or other grease to adhere to the
O-ring
Insert the O-ring to the water pipe, and coat the outer portion of
the O-ring with water or engine coolant.
.
>>B<< ENGINE COOLANT TEMPERATURE
SENSOR INSTALLATION
Apply the specified sealant to the thread of the engine coolant
temperature sensor, and then tighten it to the specified torque.
Specified Sealant: 3M
AAD Part No. 8731 or equiva-
lent
.
>>C<< RADIATOR UPPER HOSE CONNECTION
1. Insert each hose as far as the projection of the water outlet
fitting.
2. Align the mating marks on the radiator hose and hose
clamp, and then connect the radiator hose.
INSPECTIONM1141003400337.
Water Pipe and Hose Check
Check the water pipe and hose for cracks, damage and clogs.
Replace them if necessary.

SPECIFICATIONS
ENGINE COOLING14-43
SERVICE SPECIFICATIONM1141000300449
CAPACITIESM1141005100138
SEALANTSM1141000500368
ITEM STANDARD VALUE LIMIT
Fan Controller V A/C OFF 1 or less -
A/C ON Repeat
8.2
2.6
System voltage
2.6-
High-pressure valve opening pressure of radiator cap kPa (psi) 93
123 (14 18) Minimum 83 (12)
Thermostat Valve opening temperature
of thermostat
C (F)3.8L Engine 88
1.5 (190 3)
-
Full-opening temperature
of thermostat
C (F)3.8L Engine 100 (212)
-
Valve lift mm (in) 3.8L Engine 9.0 (0.35) or more
-
ITEM
QUANTITY dm3 (qt)
Long life antifreeze coolant or an equivalent 3.8L Engine 8.7 (9.2)
ITEM SPECIFIED SEALANT
Cylinder block drain plug 3M
AAD Part No.8731 or equivalent
Engine coolant temperature sensor

15-1
GROUP 15
INTAKE AND
EXHAUST
CONTENTS
GENERAL DESCRIPTION. . . . . . . . .15-2
INTAKE AND EXHAUST DIAGNOSIS15-2
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . 15-2
TROUBLESHOOTING STRATEGY . . . . . . 15-2
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 15-2
SYMPTOM PROCEDURES . . . . . . . . . . . . 15-2
SPECIAL TOOLS . . . . . . . . . . . . . . . .15-3
AIR CLEANER . . . . . . . . . . . . . . . . . .15-4
REMOVAL AND INSTALLATION . . . . . . . . 15-4
INTAKE MANIFOLD PLENUM . . . . .15-5
REMOVAL AND INSTALLATION . . . . . . . 15-5
INTAKE MANIFOLD . . . . . . . . . . . . . .15-7
REMOVAL AND INSTALLATION . . . . . . . . 15-7
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 15-9
EXHAUST MANIFOLD . . . . . . . . . . . .15-10
REMOVAL AND INSTALLATION . . . . . . . . 15-10
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 15-13
EXHAUST PIPE AND MAIN MUFFLER15-14
REMOVAL AND INSTALLATION . . . . . . . . 15-14
SPECIFICATIONS . . . . . . . . . . . . . . .15-16
FASTENER TIGHTENING SPECIFICATIONS15-16
SERVICE SPECIFICATION . . . . . . . . . . . . 15-18
SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . 15-18

SPECIAL TOOLS
INTAKE AND EXHAUST15-3
INSPECTION PROCEDURE 2: Abnormal Noise
DIAGNOSIS
STEP 1. Start the engine. Have an assistant stay
in the drivers seat. Raise the vehicle on a hoist.
Have the assistant rev the engine while
searching for exhaust leaks.
Q: Is any abnormal noise generated?
YES :
Go to Step 2.
NO : The procedure is complete.
STEP 2. Check for missing parts in the muffler.
Tap the muffler lightly to check for loose baffles,
etc.
Q: Are there any missing parts in the muffler?
YES :
Replace, then go to Step 1.
NO : Go to Step 3.
STEP 3. Check the hanger for cracks.
Q: Is the hanger cracked?
YES :
Replace, then go to Step 1.
NO : Go to Step 4.
STEP 4. Check for interference of the pipes and
muffler with the body.
Q: Are the pipes and muffler interfering with the
body?
YES :
Repair, then go to Step 1.
NO : Go to Step 5.
STEP 5. Check the heat protectors.
Q: Are any heat protectors loose or damaged?
YES :
Tighten or replace, then go to Step 1.
NO : Go to Step 6.
STEP 6. Check the pipes and muffler for damage.
Q: Are the pipes and muffler damaged?
YES :
Replace, then go to Step 1.
NO : There is no action to be taken.
SPECIAL TOOLSM1151000600429
TOOL TOOL NUMBER AND
NAMESUPERSESSION APPLICATION
MD998412
GuideMD998412 Installation of intake
manifold plenum
MB991953
Oxygen sensor wrench- Removal and installation
of heated oxygen sensor
MD998770
Oxygen sensor wrenchMD998770-01 or General
service toolRemoval and installation
of heated oxygen sensor