2005 MITSUBISHI 380 engine

INTAKE MANIFOLD
INTAKE AND EXHAUST15-8
REMOVAL SERVICE POINT
.
<> FUEL RAIL AND INJECTOR REMOVAL
Care must be taken when removing the fuel rail not to drop
the injector.
Remove the fuel rail with the injectors attached to it.
INSTALLATION SERVICE POINTS
.
>>A<< INTAKE MANIFOLD GASKET INSTALLA-
TION
Install the gasket with the protrusions in the position illustrated.
.
>>B<< INTAKE MANIFOLD INSTALLATION
1. Coat the intake manifold mounting studs with engine oil.
2. Tighten the intake manifold mounting nuts by the following
procedure.
.
ORDER MOUNTING NUTS TIGHTENING TORQUE
1st Right-bank nuts 6.5
1.5 Nm (58 13 in-lb)
2nd Left-bank nuts 22
1 Nm (16 1 ft-lb)
3rd Right-bank nuts 22
1 Nm (16 1 ft-lb)
4th Left-bank nuts 22
1 Nm (16 1 ft-lb)
5th Right-bank nuts 22
1 Nm (16 1 ft-lb)

INTAKE MANIFOLD
INTAKE AND EXHAUST15-9
>>C<< FUEL HIGH-PRESSURE HOSE
INSTALLATION
Be careful not to allow any engine oil to enter the fuel
rail.
Be careful not to bend the fuel high-pressure hose as it
is made of plastics.
1. When connecting the fuel high-pressure hose to the fuel rail,
apply a small amount of new engine oil to the O-ring and
then insert the fuel high-pressure hose, being careful not to
damage the O-ring.
2. While turning the fuel high-pressure hose to the left and
right, install it to the fuel rail.
3. Check that the injector turns smoothly. If it does not turn
smoothly, the O-ring may be trapped. Remove the fuel
high-pressure hose and then re-insert it into the fuel rail and
check again.
INSPECTIONM1151003100672
Check the following points; replace the part if a problem is
found.
.
Intake Manifold Check
1. Check for damage or cracking of any part.
2. Clogging of the negative pressure (vacuum) outlet port.
3. Using a straight edge and feeler gauge, check for distortion
of the cylinder head installation surface.
Standard value: 0.15 mm (0.006 inch) or less
Limit: 0.20 mm (0.008 inch)

EXHAUST MANIFOLD
INTAKE AND EXHAUST15-11

Required Special Tools:
MB991953: Oxygen Sensor WrenchMD998770: Oxygen Sensor Wrench
Pre-removal and Post-installation Operation
Air Cleaner Cover and Air Intake Duct Removal and
Installation (Refer to P.15-4).
Battery Removal and Installation
Under Cover Removal and Installation (Refer to GROUP
51, Under Cover P.51-13).
Front Exhaust Pipe, Center Exhaust Pipe Removal and
Installation (Refer to P.15-14).
Strut Tower Bar Removal and Installation (Refer to
GROUP 42, Strut Tower Bar P.42-12).
Engine Coolant Draining and Refilling (Refer to GROUP
14, On-vehicle Service Engine Coolant Replacement
P.14-27).
REMOVAL STEPS
1.
CENTER UNDER FLOOR HEAT
PROTECTOR
STEERING GEAR AND LINKAGE
PROTECTOR (REFER TO GROUP 37,
POWERSTEERING GEAR BOX AND
LINKAGE
P.37-30)
2.FRONT UNDER FLOOR HEAT
PROTECTOR
3.EXHAUST MANIFOLD STAY, RIGHT A
4.RIGHT BANK HEATED OXYGEN
SENSOR (FRONT) CONNECTOR
5.RIGHT BANK HEATED OXYGEN
SENSOR (REAR) CONNECTOR
<> >>A<<6.RIGHT BANK HEATED OXYGEN
SENSOR (FRONT)
<> >>A<<7.RIGHT BANK HEATED OXYGEN
SENSOR (REAR)
10.UPPER HEAT PROTECTOR
11 .EXHAUST MANIFOLD STAY, RIGHT B
12.EXHAUST MANIFOLD
13.EXHAUST MANIFOLD GASKET
REMOVAL 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)

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.)