2005 MITSUBISHI 380 Maintenance

00-1
GROUP 00
GENERAL
CONTENTS
HOW TO USE THIS MANUAL . . . . . .00-3
TROUBLESHOOTING GUIDELINES00-6
HOW TO USE TROUBLESHOOTING /
INSPECTION SERVICE POINTS. . . .00-7
TROUBLESHOOTING CONTENTS . . . . . . 00-7
HOW TO USE THE INSPECTION
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . 00-9
CONNECTOR MEASUREMENT SERVICE
POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-11
CONNECTOR INSPECTION SERVICE
POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-13
HOW TO COPE WITH INTERMITTENT
MALFUNCTIONS . . . . . . . . . . . . . . . . . . . . 00-14
INSPECTION SERVICE POINTS
FOR A BLOWN FUSE . . . . . . . . . . . . . . . . 00-16
HOW TO TREAT CURRENT TROUBLE . . 00-16
HOW TO TREAT PAST TROUBLE . . . . . . 00-16
AFFILIATED DTC REFERENCE
TABLE . . . . . . . . . . . . . . . . . . . . . . . .00-17
VEHICLE IDENTIFICATION . . . . . . .00-18
VEHICLE IDENTIFICATION NUMBER . . . 00-18
VEHICLE INFORMATION NUMBER LIST 00-19
VEHICLE COMPLIANCE PLATE . . . . . . . . 00-19
VEHICLE DATA PLATE . . . . . . . . . . . . . . . 00-20
AUSTRALIAN DESIGN RULES . . . . . . . . . 00-20OPTION CODES . . . . . . . . . . . . . . . . . . . . . 00-21
EXPORT CODES . . . . . . . . . . . . . . . . . . . . 00-21
TYRE AND LOADING PLACARD . . . . . . . . 00-21
ENGINE MODEL STAMPING . . . . . . . . . . . 00-22
PRECAUTIONS BEFORE SERVICE .00-22
SUPPLEMENTAL RESTRAINT
SYSTEM (SRS . . . . . . . . . . . . . . . . . . . . . . 00-22
HOW TO PERFORM VEHICLE
IDENTIFICATION NUMBER (VIN) WRITING00-23
SERVICING ELECTRICAL SYSTEM . . . . . 00-24
VEHICLE WASHING . . . . . . . . . . . . . . . . . . 00-24
APPLICATION OF ANTI-CORROSION
AGENTS AND UNDERCOATS . . . . . . . . . . 00-25
DIAGNOSTIC TOOL (MUT-III) . . . . . . . . . . 00-25
TOWING AND HOISTING. . . . . . . . . .00-26
GENERAL DATA AND
SPECIFICATIONS . . . . . . . . . . . . . . .00-31
TIGHTENING TORQUE . . . . . . . . . . .00-32
LUBRICATION AND MAINTENANCE 00-34
RECOMMENDED LUBRICANTS AND
LUBRICANT CAPACITIES TABLE . .00-35
Continued on next page

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 THIS MANUAL
GENERAL00-3
HOW TO USE THIS MANUALM1001000100897
MAINTENANCE, REPAIR AND
SERVICING EXPLANATIONS
This manual provides explanations, etc. concerning
procedures for the inspection, maintenance, repair
and servicing of the subject model. Unless otherwise
specified, each service procedure covers all models.
Procedures covering specific models are identified
by the model codes, or similar designation (engine
type, transaxle type, etc). A description of these des-
ignations is covered in this manual under "VEHICLE
IDENTIFICATION."
.
ON-VEHICLE SERVICE
The "ON-VEHICLE SERVICE" section has proce-
dures for performing inspections and adjustments of
particularly important components. These proce-
dures are done with regard to maintenance and ser-
vicing, but other inspections (looseness, play,
cracking, damage, etc.) must also be performed.
.
SERVICE PROCEDURES
The service steps are arranged in numerical order.
Attention to be paid in performing vehicle service are
described in detail in SERVICE POINTS.
DEFINITION OF TERMS
.
STANDARD VALUE
Indicates the value used as the standard for judging
whether or not a part or adjustment is correct.
.
LIMIT
Shows the maximum or minimum value for judging
whether or not a part or adjustment is acceptable.
.
REFERENCE VALUE
Indicates the adjustment value prior to starting the
work (presented in order to facilitate assembly and
adjustment procedures, and so they can be com-
pleted in a shorter time).
.
DANGER, WARNING, AND CAUTION
DANGER, WARNING, and CAUTION call special
attention to a necessary action or to an action that
must be avoided. The differences among DANGER,
WARNING, and CAUTION are as follows:
If a DANGER is not followed, the result is severe
bodily harm or even death.
If a WARNING is not followed, the result could be
bodily injury.
If a CAUTION is not followed, the result could be
damage to the vehicle, vehicle components or
service equipment.
TIGHTENING TORQUE INDICATION
The tightening torque indicates a median and its tol-
erance by a unit of N
m (in-lb.) or Nm (ft.-lb.). For
fasteners with no assigned torque value, refer to
P.00-32.
SPECIAL TOOL NOTE
Only MMC special tool part numbers are called out in
the repair sections of this manual. Please refer to the
special tool cross-reference chart located at the
beginning of each group, for the special tool number
that is available in your market.
ABBREVIATIONS
The following abbreviations are used in this manual
for classification of model types:
A/T:Automatic transaxle, or models equipped with
automatic transaxle.
MPI: Multipoint fuel injection, or engines equipped
with multiport fuel injection.
A/C: Air conditioning.
3.8L engine: 3.8 litre <6G75> engine, or a model
equipped with such an engine.
ABS: Anti-lock Braking System
TCL: Traction Control System
ECU: Electronic Control Unit
V.C.I.: Vehicle Communication Interface
SWS: Simplified Wiring System
CAN: Controller Area Network
M/T: Manual Transmission
SRS: Supplemental Restraint System

LUBRICATION AND MAINTENANCE
GENERAL00-34
LUBRICATION AND MAINTENANCEM1001001200336
Maintenance and lubrication service recommenda-
tions have been compiled to provide maximum pro-
tection for the vehicle owner's investment against all
reasonable types of driving conditions. Since these
conditions vary with the individual vehicle owner's
driving habits, the area in which the vehicle is oper-
ated and the type of driving to which the vehicle is
subjected, it is necessary to prescribe lubrication and
maintenance service on a time frequency as well as
mileage interval basis.
Oils, lubricants and greases are classified and
graded according to standards recommended by the
Society of Automotive Engineers (SAE) and the Aus-
tralian Petroleum Institute (API).
MAINTENANCE SCHEDULES
For Information on service maintenance refer to the
"Service handbook".
ENGINE OIL
Tests have shown that laboratory animals
develop skin cancer after prolonged contact with
used engine oil. Accordingly, the potential exists
for humans to develop a number of skin disor-
ders, including cancer, from such exposure to
used engine oil. Therefore, when changing
engine oil, be careful not to touch it as much as
possible. Protective clothing and gloves, that
cannot be penetrated by oil, should be worn. The
skin should be thoroughly washed with soap and
water, or use waterless hand cleaner, to remove
any used engine oil. Do not use petrol, thinners,
or solvents.Either of the following engine oils should be used:
1. Engine oil conforming to the ACEA classification:
"For service A1, A2 or A3.
2. Engine oil conforming to the API classification:
"For service SG" or higher.
FUEL USAGE STATEMENT
Using leaded petrol in this car will damage the
catalytic converters and heated oxygen sensors,
and affect the warranty coverage validity.
This vehicle must use unleaded petrol only.
This vehicle has a fuel filler tube which is especially
designed to accept only the smaller-diameter
unleaded petrol dispensing nozzle.
The 3.8L model is designed to operate on unleaded
petrol having an octane rating (DIN 51607) of 90
RON or higher.
.
PETROL CONTAINING ALCOHOL
Some petrol sold at service stations contain alcohol
although they may not be so identified.
Using fuels containing alcohol is not recommended
unless the nature of the blend can be determined as
being satisfactory, as follows.
Gasohol: A mixture of 10% ethanol and 90%
unleaded gasoline may be used in your vehicle. If
driveability problems are experienced as a result of
using gasohol, it is recommended that the vehicle be
operated on petrol.
Methanol: Do not use petrol containing methanol
(wood alcohol). Using this type of alcohol can result
in vehicle performance deterioration and damage
critical parts in the fuel system components. Fuel
system damage and performance problems resulting
from the use of petrol containing methanol may not
be covered by the new vehicle warranty.
MATERIALS ADDED TO FUEL
Indiscriminate use of fuel system cleaning agents
should be avoided. Many materials intended for gum
and varnish removal may contain highly active sol-
vents or similar ingredients that can be harmful to
gasket and diaphragm materials used in fuel system
component parts.

MAINTENANCE SERVICE
GENERAL00-37
MAINTENANCE SERVICE
1. FUEL SYSTEM (TANK, PIPE LINE AND
CONNECTION, AND FUEL TANK FILLER TUBE
CAP) (CHECK FOR LEAKS)
M1001001600312
Check for damage or leakage in the fuel lines and connections.
2. FUEL HOSES (CHECK CONDITION)M1001001700308
1. Inspect the surface of fuel hoses for heat and mechanical
damage. Hard and brittle rubber, cracking, tears, cuts,
abrasions and excessive swelling indicate deterioration of
the rubber.
2. If the fabric casing of the rubber hose is exposed by cracks
and abrasions in the fuel system, the hose should be
replaced.
3. AIR CLEANER FILTER (REPLACE)M1001001800338
The air cleaner element will become dirty during use, reducing
its effectiveness. Replace it with a new one.
REPLACEMENT OF AIR CLEANER ELEMENT
1. Unclamp the air cleaner housing cover.
2. Remove the air cleaner element and install a new one.
3. When clamping the air cleaner housing cover in place, be
sure that the cover is completely closed.
4. EVAPORATIVE EMISSION CANISTER (CHECK
FOR CLOGGING)
M1001001900324
If the fuel-vapor cannister is clogged or damaged, excess fuel
vapor will escape into the atmosphere causing a strong fuel
vapour smell t emitt from engine compartmrnt. emission. Dis-
connect the line at both ends, and blow it clean with com-
pressed air. Remove the fuel tank filler tube cap from the filler
tube and check to see if there is evidence that the seal makes
improper contact to the filler tube.

MAINTENANCE SERVICE
GENERAL00-38
5. SPARK PLUGS (REPLACE)M1001002000346
Iridium plugs are used. Use care not to damage the iridium
tips of the plugs. Do not adjust the spark plug gap.
1. Spark plugs must spark properly to assure proper engine
performance and reduce exhaust emission level. Therefore,
they should be replaced periodically with new ones( Refer to
Maintainence Schedule).
Spark plug type
2. The new plugs should be checked for the proper gap.
Spark plug gap: 1.0
1.1 mm
3. Install the spark plugs and tighten to 25
5 Nm (18 4
ft-lb).
6. TIMING BELT (REPLACE)M1001002300273
Replace the belt with a new one according to the vehicle main-
tenance schedule to assure proper engine performance.
<3.8L ENGINE>
For removal and installation procedures, refer to GROUP 11C,
Engine Mechanical <3.8L Engine>
Timing Belt Removal
and Installation P.11A-46.MAKER 3.8L ENGINE
BOSCH FR8DI30

MAINTENANCE SERVICE
GENERAL00-39
7. DRIVE BELTS (FOR ALTERNATOR, POWER
STEERING PUMP AND AIR CONDITIONING)
(CHECK)
M1001008700031
ALTERNATOR DRIVE BELT TENSION CHECK
<3.8L ENGINE>
.
WHEN USING DIAGNOSTIC TOOL (MUT-III)
Required Special Tools:
MB991668: Belt Tension Meter Set
Diagnostic Tool (MUT-III)
MB991824: Vehicle Communication Interface (V.C.I.)
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 Belt Tension Meter Set (MB991668) to V.C.I
(MB991824).
2. Connect MUT-III Main Harness A (BLUE) (MB991910) to
V.C.I (MB991824).
3. Connect MUT-III Main Harness A (BLUE) (MB991910) to the
data link connector.
4. Turn the ignition switch to the "ON" position and select "Belt
Tension" from the menu V.C.I (MB991824) screen.

MAINTENANCE SERVICE
GENERAL00-40
The temperature of the surface of the belt should be as
close as possible to underhood temperature.
Do not let any contaminants such as water or oil get
onto the microphone.
If strong gusts of wind blow against the microphone or
if there are any loud sources of noise nearby, the val-
ues measured by the microphone may not correspond
to actual values.
If the microphone is touching the belt while the mea-
surement is being made, the values measured by the
microphone may not correspond to actual values.
Do not take the measurement while the vehicle's engine
is running.
5. Hold special tool MB991668 (microphone) to the middle of
the drive belt between the pulleys (at the place indicated by
the arrow), about 10
20 mm (0.4 0.8 inch) away from the
rear surface of the belt and so that it is perpendicular to the
belt (within an angle of
15 degree angle).
6. Gently tap the middle of the belt between the pulleys (the
place indicated by the arrow) with your finger as shown in
the illustration, and check that the vibration frequency of the
belt is within the standard value.
Standard value:
NOTE: Because the frequency depends on the belt material,
confirm Part No. shown on the reverse of the belt.
.
Part No. Vibration frequency Hz
MD368275 133
158
MN158101, MN187016 143
169