2005 MITSUBISHI 380 Workshop Manual

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

16-1
GROUP 16
ENGINE
ELECTRICAL
CONTENTS
CHARGING SYSTEM . . . . . . . .
16-2
GENERAL DESCRIPTION . . . . . .
16-2
CHARGING SYSTEM DIAGNOSIS16-3
SPECIAL TOOL . . . . . . . . . . . . . . .16-6
ON-VEHICLE SERVICE. . . . . . . . .16-7
ALTERNATOR OUTPUT WIRE VOLTAGE
DROP TEST . . . . . . . . . . . . . . . . . . . . . 16-7
OUTPUT CURRENT TEST . . . . . . . . . . 16-8
REGULATED VOLTAGE TEST . . . . . . . 16-10
WAVE PATTERN CHECK USING AN
OSCILLOSCOPE . . . . . . . . . . . . . . . . . . 16-11
ALTERNATOR ASSEMBLY . . . . .16-14
REMOVAL AND INSTALLATION . . . . . 16-14
DISASSEMBLY AND ASSEMBLY. . . . . 16-15
INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-17
STARTING SYSTEM . . . . . . . . .16-20
GENERAL DESCRIPTION . . . . . .
16-20
STARTING SYSTEM DIAGNOSIS . . . . 16-21
STARTER MOTOR ASSEMBLY . .16-23
REMOVAL AND INSTALLATION . . . . . 16-23
INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-24
DISASSEMBLY AND ASSEMBLY. . . . . 16-26
INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-28
IGNITION SYSTEM . . . . . . . . . . . . . .16-30GENERAL DESCRIPTION . . . . . . .
16-30
SPECIAL TOOLS . . . . . . . . . . . . . .16-30
ON-VEHICLE SERVICE . . . . . . . . .16-31
KNOCK CONTROL SYSTEM CHECK . . 16-31
IGNITION COIL CHECK. . . . . . . . . . . . . 16-31
SPARK PLUG TEST . . . . . . . . . . . . . . . 16-32
SPARK PLUG CHECK AND CLEANING16-32
CAMSHAFT POSITION SENSOR CHECK16-32
CRANKSHAFT POSITION SENSOR
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . 16-32
IGNITION COIL . . . . . . . . . . . . . . . .16-33
REMOVAL AND INSTALLATION . . . . . 16-33
CAMSHAFT POSITION SENSOR .16-34
REMOVAL AND INSTALLATION . . . . . 16-34
CRANKSHAFT POSITION SENSOR16-35
REMOVAL AND INSTALLATION . . . . . 16-35
KNOCK SENSOR . . . . . . . . . . . . . .16-36
REMOVAL AND INSTALLATION . . . . . 16-36
SPECIFICATIONS . . . . . . . . . . 16-38
FASTENER TIGHTENING
SPECIFICATIONS . . . . . . . . . . . . .
16-38
GENERAL SPECIFICATIONS . . . .16-38
SERVICE SPECIFICATIONS . . . . .16-39

16-2
CHARGING SYSTEM
GENERAL DESCRIPTIONM1161000100629
The charging system charges the battery with the
alternator output to keep the battery charged at a
constant level during varying electrical load.
OPERATION
Rotation of the excited field coil generates AC volt-
age in the stator.
This alternating current is rectified through diodes to
DC voltage having a waveform shown in the illustra-
tion above.
The average output voltage fluctuates slightly with
the alternator load condition.When the ignition switch is turned on, current flows in
the field coil and initial excitation of the field coil
occurs.
When the stator coil begins to generate power after
the engine is started, the field coil is excited by the
output current of the stator coil.
The alternator output voltage rises as the field cur-
rent increases and it falls as the field current
decreases. When the battery positive voltage
(alternator S terminal voltage) reaches a regulated
voltage of approximately 14.4 V, the field current is
cut off. When the battery positive voltage drops
below the regulated voltage, the voltage regulator
regulates the output voltage to a constant level by
controlling the field current.
In addition, when the field current is constant, the
alternator output voltage rises as the engine speed
increases.

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 ELECTRICAL16-4
STEP 4.
Q: Does the alternator malfunction light go out after
starting the engine?
YES : Go to Step 5.
NO : Check the alternator (Refer to Charging System

Alternator Assembly
Inspection P.16-17.)
STEP 5.
Q: Is an oscilloscope available?
YES : Go to Step 6.
NO : Go to Step 7.
STEP 6.
Q: Does the oscilloscope show a normal wave pattern?
(Refer to Charging System
On-vehicle Service Wave
Pattern Check Using an Oscilloscope P.16-11.)
YES : Go to Step 7.
NO : Check the alternator. (Refer to Charging System

Alternator Assembly
Inspection P.16-17.)
STEP 7.
Engine: 2,500 r/min
Headlight: ON (high beam)
Voltage between alternator terminal B and the positive bat-
tery terminal
OK: 0.5 V or less
Voltage between the negative battery terminal and
alternator body
OK: 0.5 V or less
Q: Are the alternator output wire and ground wire in good
condition?
YES : Go to Step 8.
NO : Check the alternator output wire and ground wire.
STEP 8.
Q: Is the output current normal? (Refer to Charging
System
On-vehicle Service Output Current Test
P.16-8.)
YES : Go to Step 9.
NO : Check the alternator (Refer to Charging System

Alternator Assembly
Inspection P.16-17.)

CHARGING SYSTEM
ENGINE ELECTRICAL16-5
STEP 9.
Q: Is the regulated voltage normal? (Refer to Charging
System
On-vehicle Service Regulated Voltage Test
P.16-10.)
YES : Go to Step 10.
NO : Check the alternator (Refer to Charging System

Alternator Assembly
Inspection P.16-17.)
STEP 10.
Q: Is the voltage drop in the alternator output wire normal?
YES : Alternator is normal. Check other systems.
NO : Check the output wire.

CHARGING SYSTEM
ENGINE ELECTRICAL16-6
SPECIAL TOOLM1161000600486
TOOL TOOL NUMBER AND
NAMESUPERSESSION APPLICATION
Diagnostic tool (MUT-III)
A: MB991824
Ve h i c l e
communication
interface (V.C.I.)
B: MB991827
MUT-III USB cable
C: MB991910
MUT-III main harness
A (Vehicles with CAN
communication
system)
D: MB991911
MUT-III main harness
B (Vehicles without
CAN communication
system)
E: MB991914
MUT-III main harness
C (for Daimler Chrysler
models only)
F: MB991825
MUT-III measurement
adapter
G: MB991826
MUT-III trigger
harnessMB991824-KIT
NOTE: G: MB991826
MUT-III Trigger Harness
is not necessary when
pushing V.C.I. ENTER
key.Checking of engine
speed
For vehicles with CAN
communication, use
MUT-III main harness A
to send simulated
vehicle speed. If you
connect MUT-III main
harness B instead, the
CAN communication
does not function
correctly.
MB998467
Alternator harness
connectorMIT530
Micrd 530 charging
system tester.Checking of alternator
("S" terminal voltage)

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.