charging MITSUBISHI 380 2005 User Guide
[x] Cancel search | Manufacturer: MITSUBISHI, Model Year: 2005, Model line: 380, Model: MITSUBISHI 380 2005Pages: 1500, PDF Size: 47.87 MB
Page 846 of 1500
ON-VEHICLE SERVICE
HEATER, AIR CONDITIONING AND VENTILATION55-145
LOST CHARGE
If the system has lost all of its refrigerant charge due to a leak:
1. Evacuate the system. (Refer to P.55-142).
2. Charge the system with approximately 0.453 kg (1 pound) of
refrigerant.
3. Check for leaks.
4. Discharge the system.
5. Repair leaks.
Replacement filter-dryer units must be sealed while in
storage. The dryer used in these units will saturate water
quickly upon exposure to the atmosphere. When installing
a dryer, have all tools and supplies ready for quick assem-
bly to avoid keeping the system open any longer than nec-
essary.
6. Replace receiver dryer. (Refer toP.55-168).
7. Evacuate and charge system.
LOW CHARGE
If the system has not lost all of its refrigerant charge; locate and
repair all leaks. If it is necessary to increase the system pres-
sure to find the leak (because of an especially low charge) add
refrigerant. If it is possible to repair the leak without discharging
the refrigerant system, use the procedure for correcting low
refrigerant level.
HANDLING TUBING AND FITTINGS
Kinks in the refrigerant tubing or sharp bends in the refrigerant
hose lines will greatly reduce the capacity of the entire system.
High pressures are produced in the system when it is operat-
ing. Extreme care must be exercised to make sure that all con-
nections are pressure tight. Dirt and moisture can enter the
system when it is opened for repair or replacement of lines or
components. The following precautions must be observed. The
system must be completely discharged before opening any fit-
ting of connection in the refrigeration system. Open fittings with
caution even after the system has been discharged. If any
pressure is noticed as a fitting is loosened, allow trapped pres-
sure to bleed off very slowly.
Never attempt to rebend formed lines to fit. Use the correct line
for the installation you are servicing. A good rule for the flexible
hose lines is keep the radius of all bends at least 10 times the
diameter of the hose.
Page 852 of 1500
HEATER UNIT, HEATER CORE, BLOWER ASSEMBLY AND EVAPORATOR UNIT
HEATER, AIR CONDITIONING AND VENTILATION55-151
HEATER UNIT, HEATER CORE, BLOWER ASSEMBLY AND
EVAPORATOR UNIT
REMOVAL AND INSTALLATIONM1552021400012
Before removing the front seat assembly, refer to GROUP 52B, Service Precautions
P.52B-16 and Air Bag Module and Clock Spring P.52B-237.
Pre-removal and Post-installation Operation
Refrigerant draining and Refilling (Refer to Charging and
Discharging P.55-142).
Engine coolant Draining and Refilling (Refer to GROUP
00, Engine coolant P.00-47).
Instrument Panel Removal and Installation (Refer to
GROUP 52A, Instrument Panel P.52A-4).
Steering Column Shaft Assembly Removal and Installa-
tion (Refer to GROUP 37A, Steering ShaftP.37-25).
Floor Console Removal and Installation (Refer to GROUP
52A, Floor Console P.52A-10).
Front Seat Assembly Removal and Installation (Refer to
GROUP 52A, Front Seat P.52A-21).
² Strut Tower Bar (Refer to GROUP 42, Removal And
InstallationP.42-12.)
REMOVAL STEPS
BATTERY
AIR CLEANER BODY (REFER TO
GROUP 15, AIR CLEANER
P.15-4.)
1. HEATER HOSE CONNECTION
<>2. SUCTION PIPE CONNECTION
<>3. LIQUID PIPE CONNECTION
4. O-RING
REAR HEATER DUCT A AND B
(REFER TO P.55-175.)
5. JUNCTION BLOCKREMOVAL STEPS (Continued)
Page 865 of 1500
COMPRESSOR ASSEMBLY AND DRIVE BELT
HEATER, AIR CONDITIONING AND VENTILATION55-164
COMPRESSOR ASSEMBLY AND DRIVE BELT
REMOVAL AND INSTALLATIONM1552004100289
Pre-removal Operation
Refrigerant Discharging (Refer to P.55-142).
Front Bumper Under Cover (Refer to GROUP 51, FRONT
BUMPERP.51-2).
Front Under Cover RH (Refer to GROUP 51, UNDER
COVER P.51-13).Post-installation Operation
Drive Belt Tension Adjustment (Refer to GROUP 00,
Maintenance Service
Drive Belt P.00-39).
Refrigerant Charging (Refer to P.55-142).
Front Bumper Under Cover (Refer to GROUP 51, FRONT
BUMPERP.51-2).
Front Under Cover RH (Refer to GROUP 51, UNDER
COVER P.51-13).
REMOVAL STEPS
<>>>A<<1. FLEXIBLE SUCTION HOSE
CONNECTION
<>2. FLEXIBLE DISCHARGE HOSE
CONNECTION
3. O-RING4. DRIVE BELT
<> >>B<<5. A/C COMPRESSOR
6. ALTERNATOR
7. A/C COMPRESSOR BRACKETREMOVAL STEPS (Continued)
Page 871 of 1500
REFRIGERANT LINE
HEATER, AIR CONDITIONING AND VENTILATION55-170
REFRIGERANT LINE
REMOVAL AND INSTALLATIONM1552006400446
Pre-removal and Post-installation Operation
Refrigerant Draining and Refilling (Refer to Charging and
Discharging P.55-142).
Radiator Grille Removal and Installation (Refer to
GROUP 51, Radiator Grilles P.51-6).
REMOVAL STEPS
<>1. FLEXIBLE DISCHARGE HOSE
<> >>A<<2. FLEXIBLE SUCTION HOSE
<> >>A<<3. SUCTION PIPE
<>4. LIQUID PIPE
<>5. A/C PRESSURE SENSOR
9. EXPANSION VALVE JOINT
<>10. EXPANSION VALVE
11 . O - R I N GREMOVAL STEPS (Continued)
Page 978 of 1500
16-1
GROUP 16
ENGINE
ELECTRICAL
CONTENTS
CHARGING SYSTEM . . . . . . . .
16-2
GENERAL DESCRIPTION . . . . . .
16-2
CHARGING SYSTEM DIAGNOSIS16-3
SPECIAL TOOL . . . . . . . . . . . . . . .16-6
ON-VEHICLE SERVICE. . . . . . . . .16-7
ALTERNATOR OUTPUT WIRE VOLTAGE
DROP TEST . . . . . . . . . . . . . . . . . . . . . 16-7
OUTPUT CURRENT TEST . . . . . . . . . . 16-8
REGULATED VOLTAGE TEST . . . . . . . 16-10
WAVE PATTERN CHECK USING AN
OSCILLOSCOPE . . . . . . . . . . . . . . . . . . 16-11
ALTERNATOR ASSEMBLY . . . . .16-14
REMOVAL AND INSTALLATION . . . . . 16-14
DISASSEMBLY AND ASSEMBLY. . . . . 16-15
INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-17
STARTING SYSTEM . . . . . . . . .16-20
GENERAL DESCRIPTION . . . . . .
16-20
STARTING SYSTEM DIAGNOSIS . . . . 16-21
STARTER MOTOR ASSEMBLY . .16-23
REMOVAL AND INSTALLATION . . . . . 16-23
INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-24
DISASSEMBLY AND ASSEMBLY. . . . . 16-26
INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-28
IGNITION SYSTEM . . . . . . . . . . . . . .16-30GENERAL DESCRIPTION . . . . . . .
16-30
SPECIAL TOOLS . . . . . . . . . . . . . .16-30
ON-VEHICLE SERVICE . . . . . . . . .16-31
KNOCK CONTROL SYSTEM CHECK . . 16-31
IGNITION COIL CHECK. . . . . . . . . . . . . 16-31
SPARK PLUG TEST . . . . . . . . . . . . . . . 16-32
SPARK PLUG CHECK AND CLEANING16-32
CAMSHAFT POSITION SENSOR CHECK16-32
CRANKSHAFT POSITION SENSOR
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . 16-32
IGNITION COIL . . . . . . . . . . . . . . . .16-33
REMOVAL AND INSTALLATION . . . . . 16-33
CAMSHAFT POSITION SENSOR .16-34
REMOVAL AND INSTALLATION . . . . . 16-34
CRANKSHAFT POSITION SENSOR16-35
REMOVAL AND INSTALLATION . . . . . 16-35
KNOCK SENSOR . . . . . . . . . . . . . .16-36
REMOVAL AND INSTALLATION . . . . . 16-36
SPECIFICATIONS . . . . . . . . . . 16-38
FASTENER TIGHTENING
SPECIFICATIONS . . . . . . . . . . . . .
16-38
GENERAL SPECIFICATIONS . . . .16-38
SERVICE SPECIFICATIONS . . . . .16-39
Page 979 of 1500
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.
Page 980 of 1500
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.
Page 981 of 1500
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.)
Page 982 of 1500
CHARGING SYSTEM
ENGINE ELECTRICAL16-5
STEP 9.
Q: Is the regulated voltage normal? (Refer to Charging
System
On-vehicle Service Regulated Voltage Test
P.16-10.)
YES : Go to Step 10.
NO : Check the alternator (Refer to Charging System
Alternator Assembly
Inspection P.16-17.)
STEP 10.
Q: Is the voltage drop in the alternator output wire normal?
YES : Alternator is normal. Check other systems.
NO : Check the output wire.
Page 983 of 1500
CHARGING SYSTEM
ENGINE ELECTRICAL16-6
SPECIAL TOOLM1161000600486
TOOL TOOL NUMBER AND
NAMESUPERSESSION APPLICATION
Diagnostic tool (MUT-III)
A: MB991824
Ve h i c l e
communication
interface (V.C.I.)
B: MB991827
MUT-III USB cable
C: MB991910
MUT-III main harness
A (Vehicles with CAN
communication
system)
D: MB991911
MUT-III main harness
B (Vehicles without
CAN communication
system)
E: MB991914
MUT-III main harness
C (for Daimler Chrysler
models only)
F: MB991825
MUT-III measurement
adapter
G: MB991826
MUT-III trigger
harnessMB991824-KIT
NOTE: G: MB991826
MUT-III Trigger Harness
is not necessary when
pushing V.C.I. ENTER
key.Checking of engine
speed
For vehicles with CAN
communication, use
MUT-III main harness A
to send simulated
vehicle speed. If you
connect MUT-III main
harness B instead, the
CAN communication
does not function
correctly.
MB998467
Alternator harness
connectorMIT530
Micrd 530 charging
system tester.Checking of alternator
("S" terminal voltage)