belt MITSUBISHI 380 2005 Repair Manual

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 ELECTRICAL16-7
ON-VEHICLE SERVICE
ALTERNATOR OUTPUT WIRE VOLTAGE DROP TESTM1161000900669
Required Special Tool:
: Diagnostic Tool (MUT-III)
MB991824: V.C.I.
MB991827: MUT-III USB Cable
MB991910: MUT-III Main Harness A
This test determines whether the wiring from the
alternator "B" terminal to the positive battery terminal
(including the fusible link) is in good condition or not:
Battery posts, terminals and related acces-
sories contain lead and lead compounds.
WASH HANDS AFTER HANDLING.
1. Always be sure to check the following before the
test.
Alternator installation
Alternator drive belt tension (Refer to GROUP 00,
General
Maintenance Service Drive Belts
(For Alternator, Power Steering Pump and Air
Conditioning) (Check) P.00-39.)
Fusible link
Abnormal noise from the alternator while the
engine is running.2. Turn the ignition switch to the "LOCK" (OFF)
position.
3. Disconnect the negative battery cable.
4. Connect a clamp-type DC test ammeter with a
range of 0
100 A to the alternator "B" terminal
output wire.
NOTE: The way of disconnecting the alternator
output wire and of connecting the ammeter is pos-
sibly not found the problem that the output current
is dropping due to the insufficient connection
between terminal "B" and the output wire.
5. Connect a digital-type voltmeter between the
alternator "B" terminal and the positive battery
terminal. (Connect the positive lead of the
voltmeter to the "B" terminal, and then connect the
negative lead of the voltmeter to the positive
battery cable.)
6. Reconnect the negative battery cable.
7. Connect an engine tachometer or diagnostic tool.
8. Leave the hood open.
9. Start the engine.

CHARGING SYSTEM
ENGINE ELECTRICAL16-9
Required Special Tool:
: Diagnostic Tool (MUT-III)
MB991824: V.C.I.
MB991827: MUT-III USB Cable
MB991910: MUT-III Main Harness A
This test determines whether the alternator outputs
normal current. For best results, use a charging sys-
tem tester. If not available, follow the steps below.
Battery posts, terminals and related acces-
sories contain lead and lead compounds.
WASH HANDS AFTER HANDLING.
1. Before the test, always be sure to check the
following.
Alternator installation
Battery (Refer to GROUP 54A, Chassis Electrical
Battery On-vehicle Service Battery Check
P.54A-5.)
NOTE: The battery to be used should be slightly
discharged. The load in a fully-charged battery
will be insufficient and the test may not be able to
be carried out correctly.
Alternator drive belt tension (Refer to GROUP 00,
General
Maintenance Service Drive Belts
(For Alternator, Power Steering Pump and Air
Conditioning) (Check) P.00-39.)
Fusible link
Abnormal noise from the alternator while the
engine is running.
2. Turn the ignition switch to the "LOCK" (OFF)
position.
3. Disconnect the negative battery cable.
Never use clips to connect the wire. Loose
connections (for example, using clips) will
lead to a serious accident because of high
current.
4. Connect a clamp-type DC test ammeter with a
range of 0
120 A to the alternator "B" terminal
output wire.
5. Connect a voltmeter with a range of 0
20 V
between the alternator "B" terminal and ground.
(Connect the positive lead of the voltmeter to the
"B" terminal, and then connect the negative lead
of the voltmeter to ground.)
6. Connect the negative battery cable.
7. Connect an engine tachometer or diagnostic tool.
8. Leave the hood open.9. Check to be sure that the reading on the voltmeter
is equal to the battery positive voltage.
NOTE: If the voltage is 0 V, the cause is probably
an open circuit in the wire or fusible link between
the alternator "B" terminal and the battery positive
terminal or malfunctioning voltmeter.
10.After turning on the headlights, start the engine.
NOTE: Because the current from the battery will
soon drop after the engine is started, step 11
should be carried out as quickly as possible in
order to obtain the maximum current output value.
11.Immediately after setting the headlights to high
beam and turning the heater blower switch to the
highest position, increase the engine speed to
2,500 r/min and read the maximum current output
value displayed on the ammeter.
Limit value: 70 % of nominal current output
NOTE: For the nominal current output, refer to the
Alternator Specifications.
NOTE: The current output value will depend on
the electrical load and the temperature of the
alternator body.
NOTE: If the electrical load is small while testing,
the specified level of current may not be output
even though the alternator is normal. In such
cases, increase the electrical load by leaving the
headlights turned on for some time to discharge
the battery or by using the lighting system in
another vehicle, and then test again.
NOTE: The specified level of current also may not
be output if the temperature of the alternator body
or the ambient temperature is too high. In such
cases, cool the alternator and then test again.
12.The reading on the ammeter should be above the
limit value. If the reading is below the limit value
and the alternator output wire is normal, remove
the alternator from the engine and check the
alternator.
13.Run the engine at idle speed after the test.
14.Turn the ignition switch to the "LOCK" (OFF)
position.
15.Disconnect the engine tachometer or diagnostic
tool.
16.Disconnect the negative battery cable.
17.Disconnect the ammeter and voltmeter .
18.Connect the negative battery cable.
19.Run the engine for 10 minutes at an idle.

CHARGING SYSTEM
ENGINE ELECTRICAL16-10
REGULATED VOLTAGE TESTM1161001100666
Required Special Tools:
: Diagnostic Tool (MUT-III)
MB991824: V.C.I.
MB991827: MUT-III USB Cable
MB991910: MUT-III Main Harness A
MB998467: Alternator Harness Connector
This test determines whether the voltage regulator is
correctly controlling the alternator output voltage.
Battery posts, terminals and related acces-
sories contain lead and lead compounds.
WASH HANDS AFTER HANDLING.
1. Always be sure to check the following before the
test:
Alternator installation
Check to be sure that the battery installed in the
vehicle is fully charged. (Refer to GROUP 54A,
Chassis Electrical
Battery On-vehicle Service
Battery Check P.54A-5.)
Alternator drive belt tension (Refer to GROUP 00,
General
Maintenance Service Drive Belts
(For Alternator, Power Steering Pump and Air
Conditioning) (Check) P.00-39.)
Fusible link
Abnormal noise from the alternator while the
engine is running.2. Turn the ignition switch to the "LOCK" (OFF)
position.
3. Disconnect the negative battery cable.
4. Use the special tool (Alternator harness
connector: MB998467) to connect a digital-type
voltmeter between the alternator "S" terminal and
ground. (Connect the positive lead of the
voltmeter to the "S" terminal, and then connect the
negative lead of the voltmeter to a secure ground
or to the negative battery terminal.)
5. Connect a clamp-type DC test ammeter with a
range of 0
120 A to the alternator "B" terminal
output wire.
6. Reconnect the negative battery cable.
7. Connect an engine tachometer, or diagnostic tool.
8. Turn the ignition switch to the "ON" position and
check that the reading on the voltmeter is equal to
the battery positive voltage.
NOTE: If the voltage is 0 V, the cause is probably
an open circuit in the wire or fusible link between
the alternator "S" terminal and the battery positive
terminal or malfunctioning voltmeter.
9. Check to be sure that all lights and accessories
are off.
10.Start the engine.

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)

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).

DOOR
BODY42-39
DOOR GLASS AND REGULATOR
REMOVAL AND INSTALLATIONM1429001300326
Pre-removal Operation
Door Trim Assembly Removal (Refer to GROUP 52A
Door Trim P.52A-14).
Waterproof Film Removal (Refer to P.42-52).Post-installation Operation
Door Window Glass Adjustment (Refer to P.42-31).
Waterproof Film Installation (Refer to P.42-52).
Door Trim Assembly Installation (Refer to GROUP 52A,
Door Trim P.52A-14).
DOOR WINDOW REGULATOR
ASSEMBLY REMOVAL STEPS
DOOR BELTLINE MOLDING
(REFER TO P.42-52).1. DOOR WINDOW GLASS
2. WINDOW REGULATOR ASSEMBLYDOOR WINDOW REGULATOR
ASSEMBLY REMOVAL STEPS

DOOR
BODY42-41
Required Special Tool:
MB990480: Window Glass Holder
DOOR WINDOW REGULATOR
ASSEMBLY REMOVAL
<<A>>1. WINDOW REGULATOR ASSEMBLY
DOOR WINDOW GLASS REMOVAL
STEPS
DOOR WINDOW GLASS
RUNCHANNEL (REFER TO
P.42-52).
DOOR BELTLINE MOLDING
(REFER TO P.42-52).
LOWER SASH (REFER TO P.42-46).
<<B>>2. REAR DOOR STATIONARY
WINDOW GLASS ASSEMBLY
3. DOOR WINDOW GLASSDOOR WINDOW GLASS REMOVAL
STEPS (Continued)

DOOR
BODY42-53
REMOVAL
>>D<<1. DOOR WINDOW GLASS
RUNCHANNEL
WATERPROOF FILM AND DOOR
PANEL CORE REMOVAL STEPS
DOOR TRIM ASSEMBLY (REFER
TO GROUP 52A, DOOR TRIM
P.52A-14).
DOOR INSIDE HANDLE (REFER TO
P.42-46).
2. DOOR ARMREST BRACKET
>>A<<3. WATERPROOF FILM
4. DOOR PANEL CORE
DOOR OPENING INNER
WEATHERSTRIP REMOVAL
STEPS
FRONT SCUFF PLATE (REFER TO
GROUP 52A, TRIMS P.52A-11).
>>C<<5. DOOR OPENING INNER
WEATHERSTRIP (BODY SIDE)DOOR OPENING OUTER
WEATHERSTRIP REMOVAL
STEPS
DOOR CHECK MOUNTING BOLT
(BODY SIDE) (REFER TO P.42-37).
>>B<<6. DOOR OPENING OUTER
WEATHERSTRIP
DOOR BELTLINE MOLDING
REMOVAL STEPS
DOOR TRIM ASSEMBLY (REFER
TO GROUP 52A, DOOR TRIM
P.52A-14).
REMOTE CONTROLLED MIRROR
ASSEMBLY (REFER TO GROUP 51,
DOOR MIRROR P.51-28).
7. DOOR BELTLINE MOLDING

DOOR
BODY42-56
DOUBLE-SIDED TAPE POSITION
WATERPROOF FILM REMOVAL
STEPS
DOOR TRIM ASSEMBLY (REFER
TO GROUP 52A, DOOR TRIM
P.52A-14).
DOOR INSIDE HANDLE (REFER TO
P.42-46).
>>A<<4. WATERPROOF FILM
DOOR OPENING INNER
WEATHERSTRIP REMOVAL
STEPS
REAR SCUFF PLATE (REFER TO
GROUP 52A, TRIMS P.52A-11).
>>C<<5. DOOR OPENING INNER
WEATHERSTRIP (BODY SIDE)DOOR OPENING OUTER
WEATHERSTRIP REMOVAL
STEPS
DOOR CHECK MOUNTING BOLT
(BODY SIDE) (REFER TO P.42-37).
>>B<<6. DOOR OPENING OUTER
WEATHERSTRIP
DOOR BELTLINE MOLDING
REMOVAL STEPS
DOOR TRIM ASSEMBLY (REFER
TO GROUP 52A, DOOR TRIM
P.52A-14).
7. DOOR BELTLINE MOLDING