service MITSUBISHI 380 2005 Workshop Manual

CHARGING SYSTEM
ENGINE ELECTRICAL16-14
ALTERNATOR ASSEMBLY
REMOVAL AND INSTALLATION M1161001400601
REMOVAL SERVICE POINT
.
<<A>> 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
<<A>>4. A/C COMPRESSOR ASSEMBLY
<<B>>5.
ALTERNATOR ASSEMBLY REMOVAL STEPS (Continued)

CHARGING SYSTEM
ENGINE ELECTRICAL16-16
DISASSEMBLY SERVICE POINTS
.
<<A>> FRONT BRACKET ASSEMBLY REMOVAL
Do not insert a screwdriver too deep. The stator coil will be
damaged.
Insert a flat-tipped screwdriver between the front bracket
assembly and the stator core, and pry it downward to separate
the stator and front bracket assembly.
.
<<B>> ALTERNATOR PULLEY REMOVAL
Make sure not to damage the rotor.
Set the pulley upward, clamp the rotor in a vise, and remove
the pulley.
.
<<C>> STATOR REMOVAL
Check that the heat from the soldering iron is not trans-
mitted to the diode for a long time.
Use care that no undue force is exerted to leads of
diodes.
1. Use a soldering iron (180 to 250 W) to unsolder the stator.
This work should complete within approximately four
seconds to prevent heat from transferring to the diode.
2. When removing the rectifier from the regulator assembly,
unsolder the points soldered on the rectifier.

CHARGING SYSTEM
ENGINE ELECTRICAL16-17
ASSEMBLY SERVICE POINTS
.
>>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

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&#39;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
.
<<A>> 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 &#34;ON&#34;, 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&#39;t,
replace the magnetic switch.

STARTING SYSTEM
ENGINE ELECTRICAL16-27
DISASSEMBLY SERVICE POINTS
.
<<A>> 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.

IGNITION SYSTEM
ENGINE ELECTRICAL16-31
ON-VEHICLE SERVICE
KNOCK CONTROL SYSTEM CHECKM1163001800081
Check the knock sensor circuit if diagnostic trouble code, No.
P0325 is shown.
Refer to GROUP 13B, Multiport Fuel Injection (MPI)
Multiport
Fuel Injection (MPI) Diagnosis
Diagnostic Trouble Code Pro-
cedures
DTC P0325 : Knock Sensor Circuit 13A-346.
IGNITION COIL CHECK M1163001200380
Check by the following procedure, and replace the coil if there
is a malfunction.
.
PRIMARY COIL AND IGNITION POWER
TRANSISTOR CONTINUITY CHECK
NOTE: No test can be performed on the Primary side of coil.
.
SECONDARY COIL CHECK
NOTE: It is impossible to check the secondary coil through the
continuity check as a diode is integrated in the secondary coil
circuit of this ignition coil. Accordingly, check the secondary coil
in the following procedure.
1. Disconnect the ignition coil connector.
2. Remove the ignition coil and install a new spark plug to the
ignition coil.
3. Connect the ignition coil connector.
4. Disable vehicle fuel pump by removing fuel pump relay or
disconnecting fuel pump connector D-18 (under rear seat).
5. Ground the side electrode of the spark plug and crank the
engine.
6. Check that spark is produced between the electrodes of the
spark plug.
7. If no spark is produced, replace the ignition coil with a new
one and recheck.
8. If spark is produced with the new ignition coil, replace the
old one as it is faulty. If no spark is produced again, the
ignition circuit is suspected as faulty. Check the ignition
circuit.

IGNITION SYSTEM
ENGINE ELECTRICAL16-36
KNOCK SENSOR
REMOVAL AND INSTALLATION M1163002800589
Required Special Tool:
MD998773: Knock Sensor Wrench
REMOVAL SERVICE POINT
.
<<A>> KNOCK SENSOR REMOVAL
Use special tool MD998773 to remove the knock sensor.
Pre-removal and Post-installation Operation
Intake Manifold Removal and Installation (Refer to GROUP
15, Intake Manifold P.15-7).
REMOVAL
<<A>> >>A<<1. KNOCK SENSOR

IGNITION SYSTEM
ENGINE ELECTRICAL16-37
INSTALLATION SERVICE POINT
.
>>A<< KNOCK SENSOR INSTALLATION
Use special tool MD998773 to install the knock sensor.

SPECIFICATIONS
ENGINE ELECTRICAL16-39
SERVICE SPECIFICATIONSM1161000300322
ITEMS STANDARD VALUE LIMIT
Alternator
Regulated voltage
(Ambient temperature at voltage
regulator)
20C (4F)14.2 15.4
20C (68F) 13.9 14.9
60C (140F) 13.4 14.5
80C (176F) 13.1 14.5
Alternator output wire voltage drop (at 30 A) VMaximum 0.3
Nominal Output current 110A 70 % of normal output
current
Field coil resistance
Approximately 2 5
Brush protrusion length mm (in)Minimum 2 (0.08)
Starter motor
Free running characteristics Terminal voltage
V11
Current A 95
Speed r/min 2,500 or more
Pinion gap mm (in) 0.5 2.0 (0.02 0.07)
Commutator run-out mm (in) 0.05 (0.002) Minimum 0.1 (0.004)
Commutator diameter mm (in) 29.4 (1.16) Minimum 28.8 (1.13)
Undercut depth mm (in) 0.5 (0.02) Minimum 0.2 (0.008)
Ignition parts
Spark plug gap mm 1.0 1.1