electrical MITSUBISHI 380 2005 User Guide

HOW TO DIAGNOSE
GENERAL 00E-9
CABLES AND WIRES CHECKM1001005100041
1. Check connections for looseness, rust, and stains.
2. Check terminals and wires for corrosion.
3. Check terminals and wires for open circuit or impending
open circuit.
4. Check wire insulation and coating for damage, cracks, and
wear.
5. Check conductive parts of terminals for contact with other
metallic parts (vehicle body and other parts).
6. Check grounding parts to verify that there is complete
continuity between attaching bolt(s) and vehicle body.
7. Check for incorrect wiring.
8. Check that harnesses are secured to prevent contact with
sharp edges and corners or hot parts (exhaust manifold,
pipe, etc.).
9. Check that harnesses are secured firmly to provide enough
clearance from the fan pulley, fan belt, and other rotating or
moving parts.
10.Check that the harnesses between fixed parts (such as the
vehicle body) and vibrating parts (such as the engine) are
long enough to allow for vibration and movement.
BATTERY HANDLINGM1001005200048
Battery posts, terminals and related accessories con-
tain lead and lead compounds. WASH HANDS AFTER
HANDLING.
When checking or servicing does not require power from the
vehicle battery, be sure to disconnect the cable from the battery
(
) terminal. This will prevent problems that could be caused by
a short circuit. Disconnect the (
) battery terminal first and
reconnect it last.
GENERAL ELECTRICAL SYSTEM CHECKM1001005300045
A circuit consists of the power supply, switch, relay, load,
ground, etc. There are various methods to check a circuit
including an overall check, voltage check, short-circuit check,
and continuity check. Each of the methods briefly described
below applies only to circuits similar to the illustration.

HOW TO DIAGNOSE
GENERAL 00E-10
1. VOLTAGE CHECK
(1) Ground one lead wire of the test light. If a voltmeter is
used instead of the test light, ground the grounding side
lead wire.
(2) Connect the other lead wire of the test light to the power
side terminal of the switch connector. The test light
should come on or the voltmeter should indicate a
voltage.
(3) Then, connect the test light or voltmeter to the motor
connector. The test light should not come on, or the
voltmeter should indicate no voltage. When the switch is
turned ON in this state, the test light should come on, or
the voltmeter should indicate a voltage, with the motor
starting to run.
(4) The circuit illustrated here is normal. If there is any
problem, such as the motor failing to run, check voltages
beginning at the connector nearest to the motor until the
faulty part is identified.
2. SHORT-CIRCUIT CHECK
Because the fuse has blown, it is probable that there is a
short circuit. Follow the procedures below to narrow down
the short-circuit location.
STEP 1. Remove the blown fuse and connect the test light
across the fuse terminals (Circuit switch: OFF).
Q: Does the test light illuminate?
YES : Short-circuit exists between the fuse block and the
switch. Diagnose the harness between the fuse block
and the switch.
NO : Go to Step 2.

HOW TO DIAGNOSE
GENERAL 00E-11
STEP 2. Turn the switch ON and disconnect the
illumination light connector.
Q: Does the test light illuminate?
YES : Short-circuit exists between the switch and the
connector. Diagnose the harness between the switch
and the connector.
NO : Short-circuit exists between the connector and the
illumination light. Diagnose the harness between the
connector and the illumination light.

HOW TO DIAGNOSE
GENERAL 00E-12
3. CONTINUITY CHECK
(1) When the switch is in the "OFF" position and the contact
points of terminals 1 and 2 are connected, the
self-powered test light should illuminate or the ohmmeter
should read 0 ohm.
(2) When the switch is the "ON" position and the contact
points of terminals 3 and 4 are connected, the
self-powered test light should come on or the ohmmeter
should read 0 ohm.

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

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 ELECTRICAL16-5
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.

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)