2005 MITSUBISHI 380 power steering

SPECIFICATIONS
INTAKE AND EXHAUST15-18
SERVICE SPECIFICATIONM1151000300462
SEALANTSM1151000500187
Intake manifold plenum
Evaporative emission purge solenoid bolt 9.0
1.0 Nm (80 9 in-lb)
Harness bracket bolt 11
1 Nm (98 8 in-lb)
Intake manifold plenum bolt 18
2 Nm (13 2 ft-lb)
Intake manifold plenum stay bolt M8 18
2 Nm (13 2 ft-lb)
M10 36
6 Nm (27 4 ft-lb)
Manifold absolute pressure sensor bolt 5.0
1.0 Nm (44 9 in-lb)
Power steering pressure hose clamp nut 12
2 Nm (102 22 in-lb)
Power steering pressure hose clamp bracket bolt 12
2 Nm (102 22 in-lb)
Power steering oil pump bracket connecting bolt 41
8 Nm (30 6 ft-lb) ITEMSPECIFICATION
ITEM STANDARD VALUE LIMIT
Manifold distortion of the installation surface mm (in) 0.15 (0.006) or less 0.20 (0.008)
ITEM SPECIFIED SEALANT
Thermostat case assembly 3M
AAD Part No.8672, 3M AAD Part No.8679/8678 or
equivalent
Thermostat case assembly bolt 3M
AAD Part No. 8730, 8731 or equivalent

CHARGING SYSTEM
ENGINE ELECTRICAL16-3
CHARGING SYSTEM DIAGNOSISM1161000700427
TROUBLESHOOTING HINTS
Alternator malfunction light dose not go on when the ignition
switch is turned to ON, before the engine starts.
Check the bulb.
Alternator malfunction light dose not switch off after the engine
starts.
Check the IC voltage regulator inside the
alternatoralternator.
Discharged or overcharged battery.
Check the IC voltage regulator inside the alternator.
The alternator malfunction light illuminates dimly.
Check the diode (inside the combination meter) for a
short-circuit.
TROUBLESHOOTING GUIDE
The charging system troubleshooting guide is shown in the fol-
lowing steps.
STEP 1.
Q: Is the battery in good condition? (Refer to GROUP 54A,
Chassis Electrical
Battery On-vehicle Service
Battery Check P.54A-5.)
YES : Go to Step 2.
NO : Charge or replace the battery.
STEP 2.
Q: Is the alternator drive belt in good condition? (Refer to
GROUP 00, General
Maintenance Service Drive Belts
(For Alternator, Power Steering Pump and Air
Conditioning) (Check) P.00-39.)
YES : Go to Step 3.
NO : Adjust the belt tension or replace the belt.
STEP 3.
Q: Does the alternator malfunction light come on when the
ignition switch is turned on?
YES : Go to Step 4.
NO :
Check the ignition switch. (Refer to GROUP 54A,
Chassis Electrical
Ignition Switch Ignition
Switch
Inspection P.54A-44.)
Check for burnt-out alternator malfunction light.
Check the alternator. (Refer to Charging System
Alternator Assembly
Inspection P.16-17.)
Check the alternator malfunction light-related
circuits.

CHARGING SYSTEM
ENGINE ELECTRICAL16-7
ON-VEHICLE SERVICE
ALTERNATOR OUTPUT WIRE VOLTAGE DROP TESTM1161000900669
Required Special Tool:
: Diagnostic Tool (MUT-III)
MB991824: V.C.I.
MB991827: MUT-III USB Cable
MB991910: MUT-III Main Harness A
This test determines whether the wiring from the
alternator "B" terminal to the positive battery terminal
(including the fusible link) is in good condition or not:
Battery posts, terminals and related acces-
sories contain lead and lead compounds.
WASH HANDS AFTER HANDLING.
1. Always be sure to check the following before the
test.
Alternator installation
Alternator drive belt tension (Refer to GROUP 00,
General
Maintenance Service Drive Belts
(For Alternator, Power Steering Pump and Air
Conditioning) (Check) P.00-39.)
Fusible link
Abnormal noise from the alternator while the
engine is running.2. Turn the ignition switch to the "LOCK" (OFF)
position.
3. Disconnect the negative battery cable.
4. Connect a clamp-type DC test ammeter with a
range of 0
100 A to the alternator "B" terminal
output wire.
NOTE: The way of disconnecting the alternator
output wire and of connecting the ammeter is pos-
sibly not found the problem that the output current
is dropping due to the insufficient connection
between terminal "B" and the output wire.
5. Connect a digital-type voltmeter between the
alternator "B" terminal and the positive battery
terminal. (Connect the positive lead of the
voltmeter to the "B" terminal, and then connect the
negative lead of the voltmeter to the positive
battery cable.)
6. Reconnect the negative battery cable.
7. Connect an engine tachometer or diagnostic tool.
8. Leave the hood open.
9. Start the engine.

CHARGING SYSTEM
ENGINE ELECTRICAL16-9
Required Special Tool:
: Diagnostic Tool (MUT-III)
MB991824: V.C.I.
MB991827: MUT-III USB Cable
MB991910: MUT-III Main Harness A
This test determines whether the alternator outputs
normal current. For best results, use a charging sys-
tem tester. If not available, follow the steps below.
Battery posts, terminals and related acces-
sories contain lead and lead compounds.
WASH HANDS AFTER HANDLING.
1. Before the test, always be sure to check the
following.
Alternator installation
Battery (Refer to GROUP 54A, Chassis Electrical
Battery On-vehicle Service Battery Check
P.54A-5.)
NOTE: The battery to be used should be slightly
discharged. The load in a fully-charged battery
will be insufficient and the test may not be able to
be carried out correctly.
Alternator drive belt tension (Refer to GROUP 00,
General
Maintenance Service Drive Belts
(For Alternator, Power Steering Pump and Air
Conditioning) (Check) P.00-39.)
Fusible link
Abnormal noise from the alternator while the
engine is running.
2. Turn the ignition switch to the "LOCK" (OFF)
position.
3. Disconnect the negative battery cable.
Never use clips to connect the wire. Loose
connections (for example, using clips) will
lead to a serious accident because of high
current.
4. Connect a clamp-type DC test ammeter with a
range of 0
120 A to the alternator "B" terminal
output wire.
5. Connect a voltmeter with a range of 0
20 V
between the alternator "B" terminal and ground.
(Connect the positive lead of the voltmeter to the
"B" terminal, and then connect the negative lead
of the voltmeter to ground.)
6. Connect the negative battery cable.
7. Connect an engine tachometer or diagnostic tool.
8. Leave the hood open.9. Check to be sure that the reading on the voltmeter
is equal to the battery positive voltage.
NOTE: If the voltage is 0 V, the cause is probably
an open circuit in the wire or fusible link between
the alternator "B" terminal and the battery positive
terminal or malfunctioning voltmeter.
10.After turning on the headlights, start the engine.
NOTE: Because the current from the battery will
soon drop after the engine is started, step 11
should be carried out as quickly as possible in
order to obtain the maximum current output value.
11.Immediately after setting the headlights to high
beam and turning the heater blower switch to the
highest position, increase the engine speed to
2,500 r/min and read the maximum current output
value displayed on the ammeter.
Limit value: 70 % of nominal current output
NOTE: For the nominal current output, refer to the
Alternator Specifications.
NOTE: The current output value will depend on
the electrical load and the temperature of the
alternator body.
NOTE: If the electrical load is small while testing,
the specified level of current may not be output
even though the alternator is normal. In such
cases, increase the electrical load by leaving the
headlights turned on for some time to discharge
the battery or by using the lighting system in
another vehicle, and then test again.
NOTE: The specified level of current also may not
be output if the temperature of the alternator body
or the ambient temperature is too high. In such
cases, cool the alternator and then test again.
12.The reading on the ammeter should be above the
limit value. If the reading is below the limit value
and the alternator output wire is normal, remove
the alternator from the engine and check the
alternator.
13.Run the engine at idle speed after the test.
14.Turn the ignition switch to the "LOCK" (OFF)
position.
15.Disconnect the engine tachometer or diagnostic
tool.
16.Disconnect the negative battery cable.
17.Disconnect the ammeter and voltmeter .
18.Connect the negative battery cable.
19.Run the engine for 10 minutes at an idle.

CHARGING SYSTEM
ENGINE ELECTRICAL16-10
REGULATED VOLTAGE TESTM1161001100666
Required Special Tools:
: Diagnostic Tool (MUT-III)
MB991824: V.C.I.
MB991827: MUT-III USB Cable
MB991910: MUT-III Main Harness A
MB998467: Alternator Harness Connector
This test determines whether the voltage regulator is
correctly controlling the alternator output voltage.
Battery posts, terminals and related acces-
sories contain lead and lead compounds.
WASH HANDS AFTER HANDLING.
1. Always be sure to check the following before the
test:
Alternator installation
Check to be sure that the battery installed in the
vehicle is fully charged. (Refer to GROUP 54A,
Chassis Electrical
Battery On-vehicle Service
Battery Check P.54A-5.)
Alternator drive belt tension (Refer to GROUP 00,
General
Maintenance Service Drive Belts
(For Alternator, Power Steering Pump and Air
Conditioning) (Check) P.00-39.)
Fusible link
Abnormal noise from the alternator while the
engine is running.2. Turn the ignition switch to the "LOCK" (OFF)
position.
3. Disconnect the negative battery cable.
4. Use the special tool (Alternator harness
connector: MB998467) to connect a digital-type
voltmeter between the alternator "S" terminal and
ground. (Connect the positive lead of the
voltmeter to the "S" terminal, and then connect the
negative lead of the voltmeter to a secure ground
or to the negative battery terminal.)
5. Connect a clamp-type DC test ammeter with a
range of 0
120 A to the alternator "B" terminal
output wire.
6. Reconnect the negative battery cable.
7. Connect an engine tachometer, or diagnostic tool.
8. Turn the ignition switch to the "ON" position and
check that the reading on the voltmeter is equal to
the battery positive voltage.
NOTE: If the voltage is 0 V, the cause is probably
an open circuit in the wire or fusible link between
the alternator "S" terminal and the battery positive
terminal or malfunctioning voltmeter.
9. Check to be sure that all lights and accessories
are off.
10.Start the engine.

SPECIAL TOOL
POWER PLANT MOUNT32-3
SPECIAL TOOLM1321000600390
TOOL TOOL NUMBER
AND NAMESUPERSESSION APPLICATION
MB991897
Ball joint removerMB991113-01,
MB990635-01 or
General service tool Knuckle and tie rod end ball joint
disconnection
NOTE: Steering linkage puller
(MB990635 or MB991113)is also
used to disconnect the knuckle
and tie rod end ball joint.

CROSSMEMBER
POWER PLANT MOUNT32-9
CROSSMEMBER
REMOVAL AND INSTALLATIONM1321003200551
Before removing the steering wheel and air bag module assembly, always refer to GROUP 52B -
Service Precautions (P.52B-16), Air bag Module and Clock Spring (P.52B-237). Also, set the front
wheels so that they are facing straight forward, and remove the ignition key. If you fail to do this,
the SRS clock spring will be damaged, causing the SRS air bag to be inoperative and serious
injury.
*1: Indicates parts which should be initially tightened, and then fully tightened after placing the
vehicle horizontally and loading the full weight of the engine on the vehicle body.
*2: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle
on the ground in the unladen condition.
Pre-removal Operation
Power Steering Fluid Draining (Refer to GROUP 37,
On-vehicle Service Fluid Replacement P.37-18).
Power Steering Hoses Removal and Installation (Refer to
GROUP 37, Power Steering Hoses P.37A-57).
Air Bag Module and Steering Wheel Assembly Removal
(Refer to GROUP 37, Steering Wheel P.37-23).
Clock Spring Removal (Refer to GROUP 52B, Air Bag
Module and Clock Spring P.52B-237).
Floor Console Assembly Removal (Refer to GROUP 52A,
Floor Console Assembly P.52A-10).
Front Scuff Plate (LH) and Cowl Side Trim (LH) Removal
(Refer to GROUP 52A, Trims P.52A-11).
Trunk Lid Release Handle Cover Removal (Refer to
GROUP 42, Trunk Lid P.42-63).
Accelerator Stopper Removal (Refer to GROUP 17,
Accelerator Pedal P.17-9).
Front Floor Carpet Removal
Centremember Removal (Refer to P.32-7).Post-installation Operation
Centremember Installation (Refer to P.32-7).
Front Floor Carpet Installation
Accelerator Stopper Installation (Refer to GROUP 17,
Accelerator Pedal P.17-9).
Trunk Lid Release Handle Cover Installation (Refer to
GROUP 42, Trunk Lid P.42-63).
Front Scuff Plate (LH) and Cowl Side Trim (LH) Installa-
tion (Refer to GROUP 52A, Trims P.52A-11).
Floor Console Assembly Installation (Refer to GROUP
52A, Floor Console Assembly P.52A-10).
Clock Spring Installation (Refer to GROUP 52B, Air Bag
Module and Clock Spring P.52B-237).
Steering Wheel Assembly and Air Bag Module Installation
(Refer to P.37-23).
Check the dust cover for cracks or damage by pushing it
with your finger.
Power Steering Fluid Supplying (Refer to GROUP 37,
On-vehicle Service Fluid Replacement P.37-18).
Power Steering Fluid Line Bleeding (Refer to P.37-18).
Checking Steering Wheel Position with Wheels Straight
Ahead.
Front Wheel Alignment Adjustment (Refer to GROUP 33,
On-vehicle Service
Front Wheel Alignment Check and
Adjustment P.33-6).

CROSSMEMBER
POWER PLANT MOUNT32-10
REMOVAL STEPS
1. STEERING SHAFT PAD
<>2. STEERING COLUMN ASSEMBLY
AND STEERING GEAR
CONNECTION
<>3. SELF LOCKING NUTS
(CONNECTION FOR TIE ROD
END)
<>4. SELF LOCKING NUTS
(CONNECTION FOR LOWER
ARM BALL JOINT)
5. LOWER ARM ASSEMBLY
6. STABILIZER LINK CONNECTION
7. RETURN TUBE CONNECTION
8. O-RING
9. PRESSURE HOSE CONNECTION
10. O-RING
11. PRESSURE HOSE CLAMP
12. SELF LOCKING NUTS<>
13. SELF LOCKING NUTS
<> >>D<<14. FRONT AXLE CROSSMEMBER
STAY
<> >>C<<15. ENGINE REAR ROLL STOPPER
BRACKET, POWER STEERING
GEAR AND LINKAGE,
STABILIZER BAR AND FRONT
AXLE NO.1 CROSSMEMBER
ASSEMBLY
16. ENGINE REAR ROLL STOPPER
BRACKET
17. HEAT PROTECTOR "A"
18. HEAT PROTECTOR "B"
19. POWER STEERING GEAR AND
LINKAGE
>>A<<20. STABILIZER BAR
21. FRONT AXLE NO.1
CROSSMEMBER REMOVAL STEPS (Continued)