2005 MITSUBISHI 380 service

MAINTENANCE SERVICE
GENERAL00-42
ALTERNATOR DRIVE BELT TENSION
ADJUSTMENT
.1. Loosen the tensioner pulley fixing nut.
2. With the tensioner pulley fixing nut temporarily tightened to
15
5 Nm (11 4 ft-lb), set the belt tension or defection
amount to the standard value using the adjusting bolt.
Standard value:
3. Tighten the tension pulley fixing nut.
Tightening torque: 49
10 Nm (36 7 ft-lb)
POWER STEERING DRIVE BELT TENSION
CHECK
.
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)
Gently tap the middle of the belt between the pulleys (the loca-
tion 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.
NOTE: Refer to P.00-39 for details on the method of measuring
the vibration frequency using the scan tool.
Standard value:
.
ITEMS DURING
ADJUSTMENTDURING
REPLACEMENT
Vibration
frequency Hz150
163 180 202
Tension N (lb) 539
637
(121
143)785
981
(176
221)
Deflection
(Reference value)
mm (in)8.9
10.1
(0.35
0.40)6.2
7.5
(0.24
0.30)
ITEM WHEN
CHECKEDDURING
ADJUSTME
NTDURING
REPLACEM
ENT
Vibration
frequency Hz124
160 134 151 160 189

MAINTENANCE SERVICE
GENERAL00-43
WHEN USING A TENSION GAUGE
Use a belt tension gauge to check that the belt tension is within
the standard value.
Standard value:
.
BELT DEFLECTION CHECK
Apply approximately 98 N (22 lb) of force to the middle of the
drive belt between the pulleys (at the place indicated by the
arrow) and check that the amount of deflection is within the
standard value.
Standard value:
.if the tension or deflection is outside the standard value, adjust
by the following procedure.
1. Loosen the tensioner pulley lock nut.
2. Adjust the belt tension to the standard value by turning the
adjusting bolt. The tension will increase when turning the
adjusting bolt clockwise, and decrease when turning
counterclockwise.
3. Tighten the lock nut to the specified torque.
Tightening torque: 49
9 Nm (36 7 ft-lb)
4. Tighten the adjusting bolt.
Tightening torque: 5.0
1.0 Nm (44 9 in-lb)
Check after turning the crankshaft one or more rotations
clockwise.
5. Check the belt deflection amount and tension, and readjust
if necessary.
ITEM WHEN
CHECKEDDURING
ADJUSTMENTDURING
REPLACEMENT
Te n s i o n N
(lb)294 490
(66
110)343
441
(77
99)490
686
(110
154)
ITEM WHEN
CHECKEDDURING
ADJUSTMENTDURING
REPLACEMENT
Deflection
(Reference
value) mm
(in)12.3 16.2
(0.48
0.64)13.2
15.1
(0.52
0.59)9.6
12.3
(0.38
0.48)

MAINTENANCE SERVICE
GENERAL00-44
8. EXHAUST SYSTEM (CONNECTIONS PORTION
OF MUFFLER, MUFFLER PIPES AND
CONVERTER HEAT SHIELDS) (CHECK AND
SERVICE AS REQUIRED)
M1001005800299
1. Check for holes and exhaust gas leaks due to damage,
corrosion, etc.
2. Check the joints and connections for looseness and exhaust
gas leaks.
3. Check the rubber hangers and brackets for damage.
9. ENGINE OIL (CHANGE)M1001002600360
Use the specified oil. (Refer to P.00-35.)
Use care as oil could be hot.
1. After warming up the engine, remove the oil filler cap.
2. Remove the drain plug to allow the engine oil to drain.
3. Install a new drain plug gasket so that it faces in the
direction shown in the illustration, and then tighten the drain
plug to the specified torque.
Tightening torque: 39
5 Nm (29 3 ft-lb)
4. Pour new engine oil in through the oil filler hole.
Specified Engine Oil:
To ta l q u a n t i t y :
<3.8L Engine> 4.6 Litres
5. Install the engine oil filler cap.
6. Start the engine and run it at idle for a few minutes.
7. Pull out the oil dipstick slowly and check that the oil level is
within the marks on the oil dipstick.
8. Check that the oil is not excessively dirty, that there is no
coolant or petrol mixed in, and that it has sufficient viscosity.
10. ENGINE OIL FILTER (REPLACE)M1001002700345
The quality of replacement filters varies considerably. Only high
quality filters should be used to assure most efficient service.
Genuine oil filters require that the filter is capable of withstand-
ing a pressure of 1,800 kPa (261 psi) are high quality filters.
.

MAINTENANCE SERVICE
GENERAL00-45
Engine Oil Filter Selection
This vehicle is equipped with a full-flow, throw-away oil filter.
The same type of filter is recommended as a replacement filter
for this vehicle. It is possible, particularly in cold weather, that
this vehicle may develop high oil pressure for a short duration.
Make sure that any replacement filter used on this vehicle is a
high-quality filter. The filter must withstand a pressure of 1,800
kPa (261 psi) [manufacturer's specifications] to avoid filter and
ultimately engine damage. The Genuine Mitsubishi high-quality
filter and is strongly recommended for use on this vehicle.
Any replacement oil filter should be installed in accordance with
the oil filter manufacturer's installation instructions.
.
Oil Filter Replacement
Use care as oil could be hot.
1. Drain the engine oil by removing the oil drain plug.
2. Use an oil filter wrench to remove the engine oil filter.
3. Clean the filter bracket side mounting surface and ensure
the old O-ring has been removed.
4. Apply a small amount of engine oil to the O-ring of the new
oil filter.
5. Where the oil filter O-ring touches the oil pan flange, tighten
the oil filter to the specified torque using the
commercially-available tool.
Tightening torque:
: Approximately 3/4 turn [14
2 Nm]
6. Add new engine oil through the oil filler.
11. TRANSMISSION FLUIDM1001002900338
TRANSMISSION FLUID CHECK
1. Drive the vehicle until the transmission fluid temperature
rises to the normal operating temperature [70
80C (158
176
F)].
NOTE: The transmission fluid temperature is measured with
Diagnostic Tool (MUT-III).

MAINTENANCE SERVICE
GENERAL00-46
NOTE: If it takes some amount of time until the transmission
fluid reaches its normal operating temperature [70
80C
(158
176F)], check the transmission fluid level by refer-
ring to the left diagram.
2. Park the vehicle on a level surface.
3. Move the selector lever through all positions to fill the torque
converter and the hydraulic circuits with fluid, and then move
the selector lever to the "N" position.
4. After wiping off any dirt around the dipstick, remove the
dipstick and check the condition of the transmission fluid.
NOTE: If the transmission fluid smells as if it is burnt, it
means that the transmission fluid has been contaminated by
fine particles from the bushings and friction materials. Tran-
saxle overhaul and cooler line flushing may be necessary.
5. Check transmission fluid level is at the "HOT" mark on the
dipstick. If the transmission fluid level is less than this, add
DIAMOND ATF SP III until the level reaches the "HOT"
mark.
NOTE: If the transmission fluid level is too low, the oil pump
will draw in air along with the transmission fluid, which will
cause to form bubbles. If the transmission fluid level is too
high, rotating components inside the transaxle will churn the
fluid and air into a foamy liquid. Both conditions (level too
low or too high) will cause the hydraulic pressure to drop,
which will result in late shifting and slipping of the clutches
and brakes.
NOTE: In either case, air bubbles can interfere with normal
valve, clutch, and brake operation. Also, foaming can cause
transmission fluid to escape from the transaxle vent where it
may be mistaken for a leak.

MAINTENANCE SERVICE
GENERAL00-47
6. Securely insert the dipstick.
NOTE: The transmission fluid should always be replaced
under the following conditions:
.
When troubleshooting the transaxle.
When overhauling the transaxle.
When the transmission fluid is noticeably dirty or burnt
(driving under severe conditions).
TRANSMISSION FLUID CHANGE
Refer to GROUP 23A, Automatic Transmission - On-vehicle
Service P.23A-296.
12. ENGINE COOLANT (CHANGE)M1001003100357
Check the cooling system parts such as the radiator, heater
and oil cooler hoses, thermostat and their connections for leak-
age and damage.
.
CHANGING COOLANT
1. Set the temperature control knob to the "HOT" position.
2. Run the engine until the engine coolant warms, and then
stop the engine.
When removing the radiator cap, use care to avoid
contact with hot coolant or steam. Place a shop towel
over the cap and turn the cap counterclockwise a lit-
tle to let the pressure escape through the vinyl tube.
After relieving the steam pressure, remove the cap by
slowly turning it counterclockwise.
3. Drain the water from the radiator, heater core and engine
after unplugging the radiator drain plug and removing the
radiator cap.

MAINTENANCE SERVICE
GENERAL00-48
4. Drain the water in the water jacket by unplugging the drain
plug of the cylinder block.
5. Remove the radiator condenser tank assembly and drain the
coolant.
6. Drain the coolant then clean the path of the coolant by
injecting water into the radiator from the radiator cap area.
7. Apply the designated sealant to the screw area of the
cylinder block drain plug, and then tighten to the standard
torque.
Specified sealant: Loctite 577 or equivalent
Tightening torque:
<3.8L Engine> 39
5 Nm
8. Securely tighten the radiator drain plug.
9. Assemble the radiator condenser tank assembly.
Do not use alcohol or methanol anti-freeze or any engine
coolants mixed with alcohol or methanol anti-freeze. The
use of an improper anti-freeze can cause corrosion of the
aluminum components.
10.By referring to the section on coolant, select an appropriate
concentration for safe operating temperature within the
range of 30 to 60%. Use special tool MB991871 to refill the
coolant. A convenient mixture is a 50% water and 50%
antifreeze solution [freezing point:
31C (32.8 F)].
Recommended antifreeze: Long Life Antifreeze
Coolant or an equivalent
Quantity:
<3.8L Engine> 8.7 Litres
NOTE: For how to use special tool MB991871, refer to its
manufacturer’s instructions.
11.Reinstall the radiator cap.
12.Start the engine and let it warm up until the thermostat
opens.
13.After repeatedly revving the engine up to 3,000 r/min
several times, stop the engine.

MAINTENANCE SERVICE
GENERAL00-49
14.Remove the radiator cap after the engine has cooled, and
pour in coolant up to the brim. Reinstall the cap.
Do not overfill the radiator condenser tank assembly.
15.Add coolant to the radiator condenser tank assembly
between the "FULL" and "LOW" mark if necessary.
13. COOLANT HOSES (RADIATOR HOSE,
HEATER HOSE) (INSPECT)
M1001009700034
Inspect the surface of radiator hoses and heater hoses for heat
and mechanical damage. Hard and brittle rubber, cracking,
tears, cuts, abrasions and excessive swelling indicate deterio-
ration of the rubber.
14. DISC BRAKE PADS, ROTORS (INSPECT FOR
WEAR)
M1001003200291
Check for fluid contamination and wear. Replace the complete
set of pads if any one pad is defective.
Thickness of lining
Minimum limit: 2.0 mm
The pads for the right and left wheels should be replaced
at the same time. Never split or intermix brake pad sets. All
four pads must be replaced as a complete set.
15. BRAKE HOSES (CHECK FOR
DETERIORATION OR LEAKS)
M1001003400314
Inspection of brake hoses should be included in all brake ser-
vice operations.
The hoses should be checked for:
1. Incorrect length, severe surface cracking, stretching,
scuffing or worn spots (If the fabric casing of the hoses is
exposed by cracks or abrasion in the rubber hose cover, the
hoses should be replaced. Eventual deterioration of the
hose and possible bursting failure may occur).
2. Incorrect installation, twisting or interference with wheel, tyre
or chassis.