2005 MITSUBISHI 380 Workshop Manual

NOTES

21-1
GROUP 21
CLUTCH
CONTENTS
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21A
CLUTCH OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21B

NOTES

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

BODY42-2
DOOR . . . . . . . . . . . . . . . . . . . . . . . . .42-23
GENERAL DESCRIPTION . . . . . .
42-23
CENTRAL DOOR LOCKING SYSTEM
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 42-23
POWER WINDOW DIAGNOSIS . . . . . . 42-23
DOOR DIAGNOSIS . . . . . . . . . . . . . . . . 42-23
INTRODUCTION TO GLASS AND DOOR
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 42-23
GLASS AND DOOR DIAGNOSTIC
TROUBLESHOOTING STRATEGY . . . 42-23
SYMPTOM CHART . . . . . . . . . . . . . . . . 42-24
SYMPTOM PROCEDURES . . . . . . . . . 42-24
HOW TO LOCATE WIND NOISE . . . . . 42-27
SPECIAL TOOLS. . . . . . . . . . . . . .42-28
ON-VEHICLE SERVICE. . . . . . . . .42-30
DOOR FIT ADJUSTMENT. . . . . . . . . . . 42-30
DOOR WINDOW GLASS ADJUSTMENT42-31
GLASS SLIDING MECHANISM CHECK
AND ADJUSTMENT . . . . . . . . . . . . . . . 42-32
POWER WINDOW TIMER FUNCTION
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . 42-32
POWER WINDOW OPERATING
CURRENT CHECK . . . . . . . . . . . . . . . . 42-33
POWER WINDOW RELAY CHECK . . . 42-33
CIRCUIT BREAKER (INCORPORATED IN
THE POWER WINDOW MOTOR)
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-34
POWER WINDOW CHECK . . . . . . . . . . 42-34
CENTRAL DOOR LOCKING SYSTEM
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-34
DOOR OUTSIDE HANDLE PLAY CHECK42-35
DOOR INSIDE HANDLE PLAY CHECK 42-35
DOOR ASSEMBLY . . . . . . . . . . . .42-37
REMOVAL AND INSTALLATION . . . . . 42-37
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-38
DOOR GLASS AND REGULATOR42-39
REMOVAL AND INSTALLATION . . . . . 42-39
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-43
DOOR HANDLE AND LATCH . . . .42-46
REMOVAL AND INSTALLATION . . . . . 42-46
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-49
WINDOW GLASS RUNCHANNEL
AND DOOR OPENING
WEATHERSTRIP . . . . . . . . . . . . . .
42-52
REMOVAL AND INSTALLATION . . . . . . 42-52
TRUNK LID. . . . . . . . . . . . . . . . 42-60
TRUNK LID DIAGNOSIS . . . . . . . .
42-60
INTRODUCTION TO TRUNK LID
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 42-60
TRUNK LID DIAGNOSTIC
TROUBLESHOOTING STRATEGY . . . . 42-60
SYMPTOM CHART . . . . . . . . . . . . . . . . 42-60
SYMPTOM PROCEDURES . . . . . . . . . . 42-60
ON-VEHICLE SERVICE . . . . . . . . .42-61
ADJUSTMENT OF CLEARANCE
AROUND TRUNK LID . . . . . . . . . . . . . . 42-61
TRUNK LID LATCH ADJUSTMENT. . . . 42-61
TRUNK LID HEIGHT ADJUSTMENT . . . 42-62
TRUNK LID . . . . . . . . . . . . . . . . . . .42-63
REMOVAL AND INSTALLATION . . . . . . 42-63
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-65
KEYLESS ENTRY SYSTEM 42-67
GENERAL DESCRIPTION . . . . . . .
42-67
KEYLESS ENTRY SYSTEM
DIAGNOSIS . . . . . . . . . . . . . . . . . .
42-68
SPECIAL TOOL . . . . . . . . . . . . . . .42-68
ON-VEHICLE SERVICE . . . . . . . . .42-69
TRANSMITTER BATTERY CHECK . . . . 42-69
HOW TO REPLACE THE TRANSMITTER
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . 42-70
KEYLESS ENTRY SYSTEM INSPECTION42-71
KEYLESS ENTRY SYSTEM TIMER LOCK
FUNCTION INSPECTION . . . . . . . . . . . 42-71
ENABLING/DISABLING THE
ANSWERBACK FUNCTION . . . . . . . . . 42-72
HOW TO REGISTER SECRET CODE . 42-73
Continued on next page

42-3
SUNROOF ASSEMBLY . . . . . . . . . . .42-75
GENERAL DESCRIPTION . . . . . .
42-75
SUNROOF DIAGNOSIS . . . . . . . .42-75
SPECIAL TOOL . . . . . . . . . . . . . . .42-75
ON-VEHICLE SERVICE. . . . . . . . .42-75
WATER TEST . . . . . . . . . . . . . . . . . . . . 42-75
SUNROOF TIMER FUNCTION CHECK 42-76
SUNROOF FIT ADJUSTMENT . . . . . . . 42-76
SUNROOF CHECK . . . . . . . . . . . . . . . . 42-76
ROOF LID GLASS OPERATION
CURRENT CHECK . . . . . . . . . . . . . . . . 42-76
SUNROOF INITIALIZATION . . . . . . . . . 42-77
SUNROOF OPERATION CHECK . . . . . 42-77
SUNROOF ASSEMBLY. . . . . . . . .42-80
REMOVAL AND INSTALLATION . . . . . 42-80INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-82
DISASSEMBLY AND ASSEMBLY . . . . . 42-83
LOOSE PANEL . . . . . . . . . . . . 42-84
REMOVAL AND INSTALLATION .
42-84
SPECIFICATIONS . . . . . . . . . . 42-86
FASTENER TIGHTENING
SPECIFICATIONS . . . . . . . . . . . . .
42-86
SERVICE SPECIFICATIONS . . . . .42-87
SEALANT AND ADHESIVES . . . . .42-87
COMPONENT IDENTIFICATIONS .42-88

HOOD
BODY42-4
HOOD
BODY DIAGNOSIS
INTRODUCTION TO HOOD DIAGNOSISM1421005800363
Wind noise at the hood may be caused by improper
hood adjustment.
HOOD DIAGNOSTIC TROUBLESHOOTING STRATEGYM1421005900337
Use these steps to plan your diagnostic strategy. If
you follow them carefully, you will be sure that you
have exhausted most of the possible ways to find a
hood fault.
1. Gather information from the customer.2. Verify that the condition described by the
customer exists.
3. Find the malfunction by following the Symptom
Chart.
4. Verify malfunction is eliminated.
SYMPTOM CHARTM1421006000371
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Difficult Locking and Unlocking
DIAGNOSIS
STEP 1. Check that the release cable is routed
correctly.
Q: Is the release cable routed correctly?
YES :
Go to Step 2.
NO : Re-route the release cable. Then go to Step
4.
STEP 2. Check the engagement of the hood latch
and hood striker.
Q: Are the hood latch and hood striker engaged
correctly?
YES :
Go to Step 3.
NO : Adjust the hood latch (Refer to P.42-6).
Then go to Step 4.
STEP 3. Check for proper lubrication of release
cable.
Q: Is the release cable properly lubricated?
YES :
Go to Step 4.
NO : Lubricate, then go to Step 4.
STEP 4. Retest the system.
Q: Does the hood lock operate easily?
YES :
The procedure is complete.
NO : Return to Step 1. SYMPTOM INSPECTION
PROCEDUREREFERENCE PAGE
Difficult locking and unlocking 1
P.42-4
Uneven body clearance 2
P.42-5
Uneven height 3
P.42-5

HOOD
BODY42-5
INSPECTION PROCEDURE 2: Uneven Body Clearance
DIAGNOSIS
STEP 1. Check the clearance around the hood.
Q: Is the clearance around the hood even?
YES :
Go to Step 2.
NO : Adjust the hood (Refer to P.42-6). Then go
to Step 2 .
STEP 2. Retest the system.
Q: Are the clearances between body panels even?
YES :
The procedure is complete.
NO : Return to Step 1.
INSPECTION PROCEDURE 3: Uneven Height
DIAGNOSIS
STEP 1. Check the hood damper height.
Q: Is the hood damper height correct?
YES :
Go to Step 2.
NO : Adjust the hood damper (Refer to P.42-7).
Then go to Step2.
STEP 2. Retest the system.
Q: Are the hood and body height even?
YES :
The procedure is complete.
NO : Return to Step 1.