electrical MITSUBISHI 380 2005 Service Manual

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.

STARTING SYSTEM
ENGINE ELECTRICAL16-28
INSPECTIONM1162001300102.
COMMUTATOR CHECK
1. Place the armature on a pair of V-blocks, and check the
deflection by using a dial gauge.
Standard value: 0.05 mm (0.002 inch)
Limit: 0.1 mm (0.004 inch)
2. Check the outer diameter of the commutator.
Standard value: 29.4 mm (1.16 inches)
Minimum limit: 28.8 mm (1.13 inches)
3. Check the depth of the undercut between segments.
Standard value: 0.5 mm (0.02 inch)
Minimum limit: 0.2 mm (0.008 inch)
.
BRUSH CHECK
1. Check the brush for roughness of the surface that contacts
the commutator and check the brush length. Replace the
brush holder if this measurement exceeds the limit.
Minimum limit:
7.0 mm (0.28 inch)
2. If the contacting surface has been corrected or the brush
has been replaced, correct the contacting surface by
winding sandpaper around the commutator.
.

STARTING SYSTEM
ENGINE ELECTRICAL16-29
OVERRUNNING CLUTCH CHECK
1. While holding the clutch housing, rotate the pinion. The drive
pinion should rotate smoothly in one direction, but should
not rotate in the opposite direction. If the clutch does not
function properly, replace the overrunning clutch assembly.
2. Inspect the pinion for wear or burrs. If the pinion is worn or
burred, replace the overrunning clutch assembly. If the
pinion is damaged, also inspect the ring gear for wear or
burrs.
.
FRONT AND REAR BRACKET BUSHING CHECK
Inspect the bushing for wear or burrs. If the bushing is worn or
burred, replace the front bracket assembly or rear bracket
assembly.
.
ARMATURE CHECK
1. Check that the armature coil is not grounded.
2. Place the armature in a growler.
3. Hold a thin steel blade parallel and just above while rotating
the armature slowly in the growler. A shorted armature will
cause a blade to vibrate and be attracted to the core.
Replace the shorted armature.
4. Check the insulation between the armature coil cores and
the commutator segments. They are normal if there is no
continuity.
5. Check for continuity between the segments. The condition is
normal if there is continuity.

IGNITION SYSTEM
ENGINE ELECTRICAL16-30
IGNITION SYSTEM
GENERAL DESCRIPTIONM1163000100528
This system is provided with six ignition coils with
built-in ignition power transistors for each of the cylin-
ders.
Interruption of the primary current flowing in the pri-
mary side of ignition coil generates a high voltage in
the secondary side of ignition coil.
The engine control unit (ECU) controls the three
ignition power transistors to turn them alternately ON
and OFF. This causes the primary currents in the
ignition coils to be alternately interrupted and allowed
to flow to fire the cylinders in the order 1-2-3-4-5-6.The ECU determines which ignition coil should be
controlled by means of the signals from the camshaft
position sensor which is incorporated in the camshaft
and from the crankshaft position sensor which is
incorporated in the crankshaft.
It also detects the crankshaft position to provide igni-
tion at the most appropriate timing in response to the
engine operation conditions.
When the engine is cold or operated at high alti-
tudes, the ignition timing is slightly advanced to pro-
vide optimum performance.
SPECIAL TOOLSM1163000600073
TOOL TOOL NUMBER AND
NAMESUPERSESSION APPLICATION
MD998773
Knock sensor wrenchMD998773-01 Knock sensor removal
and installation

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 ELECTRICAL16-32
SPARK PLUG TESTM1163001500143
1. Remove the spark plug and connect to the ignition coil.
2. Ground the spark plug outer electrode (body), and crank the
engine.
Check that there is an electrical discharge between the
electrodes at this time.
SPARK PLUG CHECK AND CLEANING M1163004300397
Do not attempt to adjust the gap of the iridium plug.
Cleaning of the iridium plug may result in damage to
the iridium tips. Therefore, if carbon deposits must be
removed, use a plug cleaner and complete cleaning
within 20 seconds to protect the electrode. Do not use a
wire brush.
Check the plug gap and replace if the limit is exceeded.
Standard value: 0.7
0.8 mm (0.028 0.031 inch)
Limit: 1.2 mm (0.047 inch)
CAMSHAFT POSITION SENSOR CHECKM1163004400208
Refer to GROUP 13B, Multiport Fuel Injection (MPI) Multiport
Fuel Injection (MPI) Diagnosis
Diagnostic Trouble Code Pro-
cedures
DTC P0340 : Camshaft Position Sensor Circuit
13A-372.
CRANKSHAFT POSITION SENSOR CHECKM1163004500261
Refer to GROUP 13B, Multiport Fuel Injection (MPI) Multiport
Fuel Injection (MPI) Diagnosis
Diagnostic Trouble Code Pro-
cedures
DTC P0335 : Crankshaft Position Sensor Circuit
13A-354.

IGNITION SYSTEM
ENGINE ELECTRICAL16-33
IGNITION COIL
REMOVAL AND INSTALLATION M1163004000448
REMOVAL STEPS
ENGINE COVER (REFER TO
GROUP 11C, ENGINE ASSEMBLY
11A-14).
1. IGNITION COIL CONNECTORS
(LH)
2. IGNITION COILS (LH)
3. SPARK PLUGS (LH)INTAKE MANIFOLD PLENUM
(REFER TO GROUP 15, INTAKE
MANIFOLD PLENUM P.15-5).
4. IGNITION COIL CONNECTORS
(RH)
5. IGNITION COILS (RH)
6. SPARK PLUGS (RH)REMOVAL STEPS (Continued)

IGNITION SYSTEM
ENGINE ELECTRICAL16-34
CAMSHAFT POSITION SENSOR
REMOVAL AND INSTALLATION M1163003400476
REMOVAL STEPS
1. CAMSHAFT POSITION SENSOR
CONNECTOR2. CAMSHAFT POSITION SENSOR
3. O-RINGREMOVAL STEPS (Continued)

IGNITION SYSTEM
ENGINE ELECTRICAL16-35
CRANKSHAFT POSITION SENSOR
REMOVAL AND INSTALLATION M1163003500473
Pre-removal and Post-installation Operation
Timing Belt Lower Cover Removal and Installation (Refer to
GROUP 11C, Timing Belt 11A-46).

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