Battery MITSUBISHI 380 2005 Workshop Manual

ON-VEHICLE SERVICE
ENGINE COOLING14-31
FAN CONTROL RELAY CONTINUITY CHECKM1141006200310
BATTERY
VOLTAGETERMINAL NO. TO
BE CONNECTED
TO TESTERCONTINUITY TEST
RESULTS
Not applied 4
2 Open circuit
Connect
terminal No.3
and battery (
)
terminal.
Connect
terminal No.1
and battery (+)
terminal.4
2 Less than 2 ohms

THERMOSTAT
ENGINE COOLING14-35
THERMOSTAT
REMOVAL AND INSTALLATIONM1141002400475
Pre-removal and Post-installation Operation
Engine Coolant Draining and Refilling (Refer to 27).
Engine Cover Removal and Installation (Refer to GROUP
11C, Engine Assembly 11A-14).
Engine Control Unit (ECU) Removal and Installation
(Refer to GROUP 00, General 00-7).
Air Cleaner Removal and Installation (Refer to GROUP
15, Air Cleaner 4).
Strut Tower Bar Removal and Installation (Refer to
GROUP 42, Strut Tower Bar 12).
Battery and Battery Tray Removal and Installation
REMOVAL STEPS
1. LEFT BANK HEATED OXYGEN
SENSOR (REAR) CONNECTOR
2. LEFT BANK HEATED OXYGEN
SENSOR (FRONT) CONNECTOR
3. RIGHT BANK HEATED OXYGEN
SENSOR (REAR) CONNECTOR
4. RIGHT BANK HEATED OXYGEN
SENSOR (FRONT) CONNECTOR
5. THROTTLE BODY ASSEMBLY
CONNECTOR
6. EVAPORATIVE EMISSION
PURGE SOLENOID CONNECTOR7. MANIFOLD ABSOLUTE
PRESSURE SENSOR
CONNECTOR
8. POWER STEERING PRESSURE
SWITCH CONNECTOR
9. CONTROL WIRING HARNESS
AND WIRING HARNESS
COMBINATION CONNECTOR
10. KNOCK SENSOR CONNECTOR
11. CRANKSHAFT POSITION
SENSOR CONNECTOR
13. INJECTOR CONNECTORREMOVAL STEPS (Continued)

EXHAUST MANIFOLD
INTAKE AND EXHAUST15-11

Required Special Tools:
MB991953: Oxygen Sensor WrenchMD998770: Oxygen Sensor Wrench
Pre-removal and Post-installation Operation
Air Cleaner Cover and Air Intake Duct Removal and
Installation (Refer to P.15-4).
Battery Removal and Installation
Under Cover Removal and Installation (Refer to GROUP
51, Under Cover P.51-13).
Front Exhaust Pipe, Center Exhaust Pipe Removal and
Installation (Refer to P.15-14).
Strut Tower Bar Removal and Installation (Refer to
GROUP 42, Strut Tower Bar P.42-12).
Engine Coolant Draining and Refilling (Refer to GROUP
14, On-vehicle Service Engine Coolant Replacement
P.14-27).
REMOVAL STEPS
1.
CENTER UNDER FLOOR HEAT
PROTECTOR
STEERING GEAR AND LINKAGE
PROTECTOR (REFER TO GROUP 37,
POWERSTEERING GEAR BOX AND
LINKAGE
P.37-30)
2.FRONT UNDER FLOOR HEAT
PROTECTOR
3.EXHAUST MANIFOLD STAY, RIGHT A
4.RIGHT BANK HEATED OXYGEN
SENSOR (FRONT) CONNECTOR
5.RIGHT BANK HEATED OXYGEN
SENSOR (REAR) CONNECTOR
<> >>A<<6.RIGHT BANK HEATED OXYGEN
SENSOR (FRONT)
<> >>A<<7.RIGHT BANK HEATED OXYGEN
SENSOR (REAR)
10.UPPER HEAT PROTECTOR
11 .EXHAUST MANIFOLD STAY, RIGHT B
12.EXHAUST MANIFOLD
13.EXHAUST MANIFOLD GASKET
REMOVAL STEPS (Continued)

16-2
CHARGING SYSTEM
GENERAL DESCRIPTIONM1161000100629
The charging system charges the battery with the
alternator output to keep the battery charged at a
constant level during varying electrical load.
OPERATION
Rotation of the excited field coil generates AC volt-
age in the stator.
This alternating current is rectified through diodes to
DC voltage having a waveform shown in the illustra-
tion above.
The average output voltage fluctuates slightly with
the alternator load condition.When the ignition switch is turned on, current flows in
the field coil and initial excitation of the field coil
occurs.
When the stator coil begins to generate power after
the engine is started, the field coil is excited by the
output current of the stator coil.
The alternator output voltage rises as the field cur-
rent increases and it falls as the field current
decreases. When the battery positive voltage
(alternator S terminal voltage) reaches a regulated
voltage of approximately 14.4 V, the field current is
cut off. When the battery positive voltage drops
below the regulated voltage, the voltage regulator
regulates the output voltage to a constant level by
controlling the field current.
In addition, when the field current is constant, the
alternator output voltage rises as the engine speed
increases.

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 ELECTRICAL16-4
STEP 4.
Q: Does the alternator malfunction light go out after
starting the engine?
YES : Go to Step 5.
NO : Check the alternator (Refer to Charging System

Alternator Assembly
Inspection P.16-17.)
STEP 5.
Q: Is an oscilloscope available?
YES : Go to Step 6.
NO : Go to Step 7.
STEP 6.
Q: Does the oscilloscope show a normal wave pattern?
(Refer to Charging System
On-vehicle Service Wave
Pattern Check Using an Oscilloscope P.16-11.)
YES : Go to Step 7.
NO : Check the alternator. (Refer to Charging System

Alternator Assembly
Inspection P.16-17.)
STEP 7.
Engine: 2,500 r/min
Headlight: ON (high beam)
Voltage between alternator terminal B and the positive bat-
tery terminal
OK: 0.5 V or less
Voltage between the negative battery terminal and
alternator body
OK: 0.5 V or less
Q: Are the alternator output wire and ground wire in good
condition?
YES : Go to Step 8.
NO : Check the alternator output wire and ground wire.
STEP 8.
Q: Is the output current normal? (Refer to Charging
System
On-vehicle Service Output Current Test
P.16-8.)
YES : Go to Step 9.
NO : Check the alternator (Refer to Charging System

Alternator Assembly
Inspection P.16-17.)

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 ELECTRICAL16-8
10.With the engine running at 2,500 r/min, turn the
headlights and other lights on and off to adjust the
alternator load so that the value displayed on the
ammeter is slightly above 30 A.
Read the voltmeter. Voltage reading at or below
limit value means voltage drop between alternator
and battery is OK.
Limit value: maximum 0.3 V
NOTE: When the alternator output is high and the
value displayed on the ammeter does not
decrease to 30 A, set the value to 40 A. Read the
value displayed on the voltmeter at this time.
In this case the limit value becomes maximum 0.4
V.
Adjust the engine speed by gradually decreasing
it until the value displayed on the ammeter is 30
A. Take a reading of the value displayed on the
voltmeter at this time.11.If the value displayed on the voltmeter is above
the limit value, there is probably a malfunction in
the alternator output wire. Check the wiring
between the alternator "B" terminal and the
positive battery terminal (including fusible link).
If a terminal is not sufficiently tight or if the
harness has become discolored due to
overheating, repair and then test again.
12.After the test, run the engine at idle.
13.Turn off all lights and turn the ignition switch to the
"LOCK" (OFF) position.
14.Disconnect the engine tachometer or diagnostic
tool.
15.Disconnect the negative battery cable.
16.Disconnect the ammeter and voltmeter.
17.Connect the negative battery cable.
18.Run the engine for 10 minutes at an idle.
OUTPUT CURRENT TESTM1161001000670

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.