2005 MITSUBISHI 380 belt

INTAKE MANIFOLD
INTAKE AND EXHAUST15-7
INTAKE MANIFOLD
REMOVAL AND INSTALLATION M1151003000802
Pre-removal Operation
Fuel Discharge Prevention [Refer to GROUP 13B,
On-vehicle Service
Fuel Pump Relay Disconnection
(How to Reduce Pressurized Fuel Lines) 13A-663.]
Intake Manifold Plenum Removal (Refer to P.15-5.)Post-installation Operation
Intake Manifold Plenum Installation (Refer to P.15-5.)
Fuel Leakage Inspection
REMOVAL STEPS
1. INJECTOR CONNECTOR
2. ENGINE MOUNTING STAY
>>C<<3. FUEL HIGH-PRESSURE HOSE
CONNECTION
5. BLOW-BY HOSE
<>6. FUEL RAIL AND INJECTOR
7. PCV HOSE CONNECTION8. TIMING BELT FRONT UPPER
COVER, RIGHT
9. TIMING BELT FRONT UPPER
COVER, LEFT
10. WATER PUMP BRACKET>>B<<11. INTAKE MANIFOLD
>>A<<12. INTAKE MANIFOLD GASKET
13. CONTROL HARNESS CLAMPREMOVAL STEPS (Continued)

SPECIFICATIONS
INTAKE AND EXHAUST15-16
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONSM1151006800506
ITEMSPECIFICATION
Air cleaner
Air cleaner bolt 8.8
1.0 Nm (78 9 in-lb)
Air cleaner bracket bolt and nut 12
2 Nm (102 22 in-lb)
Air cleaner resonator bolt 8.8
1.0 Nm (78 9 in-lb)
Air intake hose clamp bolt 4.0
0.9 Nm (35 8 in-lb)
Airflow sensor nut 8.0
1.0 Nm
Exhaust manifold
Exhaust manifold nut 44
5 Nm (33 3 ft-lb)
Front exhaust pipe bolt 49
9 Nm (37 6 ft-lb)
Exhaust manifold stay, left A bolt M8 19
3 Nm (14 2 ft-lb)
Exhaust manifold stay, left B bolt M10 44
8 Nm (33 5 ft-lb)
Heat protector bolt 14
1 Nm (120 13 in-lb)
Heated oxygen sensor 44
5 Nm (33 3 ft-lb)
Exhaust manifold
Exhaust manifold nut 44
5 Nm (33 3 ft-lb)
Exhaust manifold stay, right A bolt M12 75
10 Nm (55 7 ft-lb)
Exhaust manifold stay, right B bolt M10 44
5 Nm (33 3 ft-lb)
Heat protector bolt 14
1 Nm (120 13 in-lb)
Heated oxygen sensor 44
5 Nm (33 3 ft-lb)
Exhaust pipe and main muffler
Crossmember stay bolt 45
5 Nm (34 3 ft-lb)
Center exhaust pipe nut 49
9 Nm (37 6 ft-lb)
Front floor backbone brace bolt 22
4 Nm (16 3 ft-lb)
Front no.1 exhaust pipe bolt 35
4 Nm (26 3 ft-lb)
Front no.1 exhaust pipe to front no.2 exhaust pipe bolt 49
4 Nm (37 3 ft-lb)
Front no.1 exhaust pipe to right bank exhaust manifold nut 49
9 Nm (37 6 ft-lb)
Front no.1 exhaust pipe to left bank exhaust manifold bolt 49
9 Nm (37 6 ft-lb)
Hanger bolt 12
2 Nm (107 17 in-lb)
Main muffler bolt 49
4 Nm (37 3 ft-lb)
Heat protector bolt 14
1 Nm (120 13 in-lb)
Intake manifold
Control harness clamp bolt 11
1 Nm (98 8 in-lb)
Engine mounting stay bolt 36
6 Nm (27 4 ft-lb)
Fuel rail and injector bolt 12
1 Nm (102 13 in-lb)
Intake manifold bolt 22
1 Nm (16 1 ft-lb)
Timing belt front upper cover bolt M6 11
1 Nm (98 8 in-lb)
M8 14
1 Nm (120 13 in-lb)

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.

CHARGING SYSTEM
ENGINE ELECTRICAL16-14
ALTERNATOR ASSEMBLY
REMOVAL AND INSTALLATION M1161001400601
REMOVAL SERVICE POINT
.
<> A/C COMPRESSOR ASSEMBLY REMOVAL
Remove the compressor from the compressor bracket with the
hose still attached.
Pre-removal and Post-installation Operation
Under Cover Removal and Installation (Refer to GROUP
51, Under Cover P.51-13).
Side Under Cover Removal and Installation (Refer to
GROUP 51, Under Cover P.51-13).
REMOVAL STEPS
1.
ALTERNATOR DRIVE BELT
2.
ALTERNATOR CONNECTOR3. A/C COMPRESSOR ASSEMBLY
CONNECTOR
<>4. A/C COMPRESSOR ASSEMBLY
<>5.
ALTERNATOR ASSEMBLY REMOVAL STEPS (Continued)