2005 MITSUBISHI 380 check engine

THERMOSTAT
ENGINE COOLING14-38
INSPECTIONM1141002500450.
Thermostat Check
1. Immerse the thermostat in water, and heat the water while
stirring. Check the thermostat valve opening temperature.
Standard value:
Valve opening temperature:
88
1.5C (190 3F)
2. Check that the amount of valve lift is at the standard value
when the water is at the full-opening temperature.
NOTE: Measure the valve height when the thermostat is
fully closed, and use this measurement to compare the
valve height when the thermostat is fully open.
Standard value:
Full-opening temperature:
100
C (212F)
Amount of valve lift:
9.0 mm (0.35 inch) or more

WATER HOSE AND WATER PIPE
ENGINE COOLING14-41
INSTALLATION SERVICE POINTS
.
>>A<< O-RING INSTALLATION
Do not allow engine oil or other grease to adhere to the
O-ring
Insert the O-ring to the water pipe, and coat the outer portion of
the O-ring with water or engine coolant.
.
>>B<< ENGINE COOLANT TEMPERATURE
SENSOR INSTALLATION
Apply the specified sealant to the thread of the engine coolant
temperature sensor, and then tighten it to the specified torque.
Specified Sealant: 3M
AAD Part No. 8731 or equiva-
lent
.
>>C<< RADIATOR UPPER HOSE CONNECTION
1. Insert each hose as far as the projection of the water outlet
fitting.
2. Align the mating marks on the radiator hose and hose
clamp, and then connect the radiator hose.
INSPECTIONM1141003400337.
Water Pipe and Hose Check
Check the water pipe and hose for cracks, damage and clogs.
Replace them if necessary.

GENERAL DESCRIPTION
INTAKE AND EXHAUST15-2
GENERAL DESCRIPTIONM1151000100446
The exhaust pipe is divided into four parts.
INTAKE AND EXHAUST DIAGNOSIS
INTRODUCTIONM1151006900321
Intake leaks usually create driveability issues that
are not obviously related to the intake system.
Exhaust leaks or abnormal noise is caused by
cracks, gaskets and fittings, or by exhaust pipe or
muffler damage due to impacts during travel. The
exhaust leaks from these sections and causes the
exhaust noise to increase. There may be cases
when the system contacts the body and vibration
noise is generated.
TROUBLESHOOTING STRATEGYM1151007000321
Use these steps to plan your diagnostic strategy. If
you follow them carefully, you will be sure that you
have exhausted most of the possible ways to find an
intake or exhaust system fault.
1. Gather information from the customer.2. Verify that the condition described by the
customer exists.
3. Find the malfunction by following the Symptom
Chart.
4. Verify malfunction is eliminated.
SYMPTOM CHARTM1151007100328
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Exhaust Leakage
DIAGNOSIS
STEP 1. Start the engine. Have an assistant stay
in the driver’s seat. Raise the vehicle on a hoist.
Have the assistant rev the engine while
searching for exhaust leaks.
Q: Is the exhaust leaking?
YES :
Go to Step 2.
NO : The procedure is complete.
STEP 2. Check the gasket for cracks, damage.
Q: Is the gasket damaged?
YES :
Replace the gasket, then go Step 1.
NO : Go to Step 3.
STEP 3. Check for loose coupling sections.
Q: Are there any loose each sections?
YES :
Tighten, then go to Step 1.
NO : There is no action to be taken. SYMPTOM INSPECTION PROCEDURE REFERENCE PAGE
Exhaust Leakage 1
P.15-2
Abnormal Noise 2
P.15-3

SPECIAL TOOLS
INTAKE AND EXHAUST15-3
INSPECTION PROCEDURE 2: Abnormal Noise
DIAGNOSIS
STEP 1. Start the engine. Have an assistant stay
in the drivers seat. Raise the vehicle on a hoist.
Have the assistant rev the engine while
searching for exhaust leaks.
Q: Is any abnormal noise generated?
YES :
Go to Step 2.
NO : The procedure is complete.
STEP 2. Check for missing parts in the muffler.
Tap the muffler lightly to check for loose baffles,
etc.
Q: Are there any missing parts in the muffler?
YES :
Replace, then go to Step 1.
NO : Go to Step 3.
STEP 3. Check the hanger for cracks.
Q: Is the hanger cracked?
YES :
Replace, then go to Step 1.
NO : Go to Step 4.
STEP 4. Check for interference of the pipes and
muffler with the body.
Q: Are the pipes and muffler interfering with the
body?
YES :
Repair, then go to Step 1.
NO : Go to Step 5.
STEP 5. Check the heat protectors.
Q: Are any heat protectors loose or damaged?
YES :
Tighten or replace, then go to Step 1.
NO : Go to Step 6.
STEP 6. Check the pipes and muffler for damage.
Q: Are the pipes and muffler damaged?
YES :
Replace, then go to Step 1.
NO : There is no action to be taken.
SPECIAL TOOLSM1151000600429
TOOL TOOL NUMBER AND
NAMESUPERSESSION APPLICATION
MD998412
GuideMD998412 Installation of intake
manifold plenum
MB991953
Oxygen sensor wrench- Removal and installation
of heated oxygen sensor
MD998770
Oxygen sensor wrenchMD998770-01 or General
service toolRemoval and installation
of heated oxygen sensor

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)

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

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.