Oil MITSUBISHI 380 2005 Service Manual

CHARGING SYSTEM
ENGINE ELECTRICAL16-17
ASSEMBLY SERVICE POINTS
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>>A<< REGULATOR ASSEMBLY INSTALLATION
After installing the regulator assembly, insert a wire through the
hole provided on the rear bracket while pressing down on the
brush, and secure the brush.
NOTE: By inserting a wire, the brush will be secured in place,
and the installation of the rotor will be easier.
.
>>B<< ROTOR ASSEMBLY INSTALLATION
After installing the rotor, remove the wire used to secure the
brush.
INSPECTIONM1161001700099.
ROTOR CHECK
1. Check the continuity between the slip rings of the field coil. If
the resistance value is not within the standard value, replace
the rotor.
Standard value: approximately 2
5

CHARGING SYSTEM
ENGINE ELECTRICAL16-18
2. Check the continuity between the slip ring and the core. If
there is continuity, replace the rotor.
.
STATOR CHECK
1. Check the continuity between the coil lead. If there is no
continuity, replace the stator.
2. Check the continuity between the coil and the core. If there
is continuity, replace the stator.
.
RECTIFIER CHECK
1. Check the continuity between the positive rectifier and the
stator coil lead connection terminal with a tester. If there is
continuity between the terminals, the diode is shorted, so
replace the rectifier.

CHARGING SYSTEM
ENGINE ELECTRICAL16-19
2. Check the continuity between the negative rectifier and the
stator coil lead connection terminal with a tester. If there is
continuity between the terminals, the diode is grounded, so
replace the rectifier.
3. Check the continuity of the three diodes by connecting an
ohmmeter to both ends of each diode. If there is continuity
between the directions, or if there is no continuity, the diode
is damaged, so replace the rectifier.
.
BRUSH CHECK
1. Replace the brush if the brush protrusion length shown in
the illustration is below the minimum limit value.
Minimum limit: 2 mm (0.08 inch)
2. The brush can be removed by unsoldering the brush lead
wire.
3. When installing a new brush, push the brush in to the brush
holder, and solder the lead wire.

STARTING SYSTEM
ENGINE ELECTRICAL16-20
STARTING SYSTEM
GENERAL DESCRIPTIONM1162000100235
If the ignition switch is turned to the "START" posi-
tion, current flows in the coil provided inside mag-
netic switch, attracting the plunger. When the plunger
is attracted, the lever connected to the plunger is
actuated to engage the starter clutch.
On the other hand, attracting the plunger will turn on
the magnetic switch, allowing the "B" terminal and
"M" terminal to conduct. Thus, current flows to
engage the starter motor.When the ignition switch is returned to the "ON" posi-
tion after starting the engine, the starter clutch is dis-
engaged from the ring gear.
An overrunning clutch is provided between the pinion
and the armature shaft, to prevent damage to the
starter.
OPERATION
When the ignition switch is switched to the "ST" posi-
tion while the selector lever is at the "P" or "N" range,
the contact (magnetic switch) of the starter is
switched ON and the starter motor is activated.

STARTING SYSTEM
ENGINE ELECTRICAL16-21
STARTING SYSTEM DIAGNOSISM1162000700293
TROUBLESHOOTING HINTS
The starter motor does not operate at all.
Battery posts, terminals and related accessories con-
tain lead and lead compounds. WASH HANDS AFTER
HANDLING.
Check the starter (coil).
Check for poor contact at the battery terminals and
starter.
Check the transmission range switch.
The starter motor doesn't stop
Check the starter (magnetic switch).
TROUBLESHOOTING GUIDE
The starting system troubleshooting guide is shown in the fol-
lowing steps.
Battery posts, terminals and related accessories con-
tain lead and lead compounds. WASH HANDS AFTER
HANDLING.
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.
Disconnect the starter motor S (solenoid) terminal connec-
tor.
Using a jumper wire, apply battery positive voltage to the
starter motor S (solenoid) terminal.
Check the engine condition.
OK: Turns normally
Q: Dose the starter motor operate normally?
YES :
Check the ignition switch (Refer to GROUP 54A,
Chassis Electrical
Ignition Switch Ignition
Switch
Inspection P.54A-44.)
Check the transmission range switch. (Refer to
GROUP 23A, Automatic Transaxle
On-vehicle
Service
Essential Service Transmission Range
Switch Check P.23A-294.)
Check the wire between the battery and starter
motor S (solenoid) terminal.
NO : Go to Step 3.

STARTING SYSTEM
ENGINE ELECTRICAL16-24
REMOVAL SERVICE POINT
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<> STARTER ASSEMBLY REMOVAL
Remove the starter assembly from under the vehicle.
INSPECTIONM1162001100197.
PINION GAP ADJUSTMENT
1. Disconnect the field coil wire from the M-terminal of the
magnetic switch.
2. Connect a 12-volt battery between the S-terminal and
M-terminal.
This test must be performed quickly (in less than 10 sec-
onds) to prevent the coil from burning.
3. Set the switch to "ON", and the pinion will move out.
4. Check the pinion-to-stopper clearance (pinion gap) with a
feeler gauge.
Standard value: 0.5
2.0 mm (0.02 0.07 inch)
5. If the pinion gap is out of specification, adjust by adding or
removing gasket(s) between the magnetic switch and front
bracket.
.
MAGNETIC SWITCH PULL-IN TEST
1. Disconnect the field coil wire from the M-terminal of the
magnetic switch.
This test must be performed quickly (in less than 10 sec-
onds) to prevent the coil from burning.
2. Connect a 12-volt battery between the S-terminal and
M-terminal.
3. If the pinion moves out, the pull-in coil is good. If it doesn't,
replace the magnetic switch.

STARTING SYSTEM
ENGINE ELECTRICAL16-25
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MAGNETIC SWITCH HOLD-IN TEST
1. Disconnect the field coil wire from the M-terminal of the
magnetic switch.
This test must be performed quickly (in less than 10 sec-
onds) to prevent the coil from burning.
2. Connect a 12-volt battery between the S-terminal and body.
3. Manually pull out the pinion as far as the pinion stopper
position.
4. If the pinion remains out, everything is operating properly. If
the pinion moves in, the hold-in circuit is open. Replace the
magnetic switch.
.
FREE RUNNING TEST
1. Place the starter motor in a vise equipped with soft jaws and
connect a fully-charged 12-volt battery to the starter motor
as follows:
2. Connect a test ammeter (100-ampere scale) and carbon pile
rheostat in series between the positive battery terminal and
starter motor terminal.
3. Connect a voltmeter (15-volt scale) across the starter motor.
4. Rotate the rheostat to full-resistance position.
5. Connect the battery cable from the negative battery terminal
to the starter motor body.
6. Adjust the rheostat until the battery positive voltage shown
on the voltmeter is 11 V.
7. Confirm that the maximum amperage is within the
specifications and that the starter motor turns smoothly and
freely.
Current: maximum 95 Amps
.
MAGNETIC SWITCH RETURN TEST
1. Disconnect the field coil wire from the M-terminal of the
magnetic switch.
This test must be performed quickly (in less than 10 sec-
onds) to prevent the coil from burning.
2. Connect a 12-volt battery between the M-terminal and body.
Be careful not to get your fingers caught when pulling
out the pinion.
3. Pull the pinion out and release. If the pinion quickly returns
to its original position, everything is operating properly. If it
doesn't, replace the magnetic switch.

STARTING SYSTEM
ENGINE ELECTRICAL16-27
DISASSEMBLY SERVICE POINTS
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<> SNAP RING AND STOP RING REMOVAL
1. Press a long socket wrench of appropriate size to the stop
ring. Then tap the socket wrench to remove the stop ring to
the pinion gear side.
2. After removing the snap ring (by using snap-ring pliers),
remove the stop ring and the overrunning clutch.
STARTER MOTOR PART CLEANING
1. Do not immerse parts in cleaning solvent. Immersing the
yoke and field coil assembly and/or armature will damage
insulation. Wipe these parts with a shop towel only.
2. Do not immerse the drive unit in cleaning solvent.
Overrunning clutch is pre-lubricated at the factory and
solvent will wash lubrication from the clutch.
3. The drive unit may be cleaned with a brush moistened with
cleaning solvent and wiped dry with a shop towel.
ASSEMBLY SERVICE POINT
.
>>A<< STOP RING AND SNAP RING INSTALLA-
TION
Using a suitable pulling tool, pull the overrunning clutch stop
ring over the snap ring.