MITSUBISHI LANCER 2005 Manual PDF

CHARGING SYSTEM
ENGINE ELECTRICAL16-7
REGULATED VOLTAGE TESTM1161001100354
This test determines whether the voltage regulator
correctly controlling the alternator output voltage.
1. Always be sure to check the following before the
test.
•Alternator installation
•Check that the battery installed in the vehicle is
fully charged.
(Refer to GROUP 54A − Battery − On-vehicle
Service − Charging P.54A-4).
•Drive belt tension
(Refer to GROUP 11A − On-vehicle Service <4G1>
P.11A-7 or GROUP 11C − On-vehicle Service
<4G6> P.11C-7.)
•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 test harness
(MB991519) to connect a digital voltmeter
between the alternator "S" terminal and earth
[Connect the (+) lead of the voltmeter to the "S"
terminal, and then connect the (-) lead of the
voltmeter to a secure earth or to the battery (-)
terminal].
5. Connect a clamp-type DC test ammeter with a
range of 0 − 120 A to the alternator "B" terminal
output wire.NOTE: The way of disconnecting the alternator
output wire and of connecting the ammeter is
possibly not found the problem that the output
current is dropping due to the insufficient
connection between terminal "B" and the output
wire.
6. Reconnect the negative battery cable.
7. Connect a tachometer or the MUT-II/III (Refer to
GROUP 11A − On-vehicle Service − Idle speed
check <4G1> P.11A-11 or GROUP 11C −
On-vehicle Service − Idle speed check <4G6>
P.11C-11).
8. Turn the ignition switch to the "ON" position and
check that the reading on the voltmeter is equal to
the battery 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 (+)
terminal.
9. Turn all lamps and accessories off.
10.Start the engine.
11.Increase the engine speed to 2,500 r/min.
12.Read the value displayed on the voltmeter when
the alternator output current alternator becomes
10 A or less.
13.If the voltage reading conforms to the value in the
voltage regulation, then the voltage regulator is
operating normally.
AK300727AB
BatteryIgnition switch
Engine-ECU <M/T>
Engine-A/T-ECU <A/T>Ammeter (clamp-type)Load
Black MB991519
Voltmeter (digital-type) Red
YellowBlueAlternator B
FR
L
S
G

CHARGING SYSTEM
ENGINE ELECTRICAL16-8
If the voltage is not within the standard value,
there is a malfunction of the voltage regulator or of
the alternator.
14.After the test, lower the engine speed to the idle
speed.
15.Turn the ignition switch to the "LOCK" (OFF)
position.
16.Remove the tachometer or the MUT-II/III.17.Disconnect the negative battery cable.
18.Disconnect the ammeter and voltmeter.
19.Connect the alternator output wire to the
alternator "B" terminal.
20.Remove the special tool, and return the connector
to the original condition.
21.Connect the negative battery cable.
Voltage Regulation Table
Standard value:
Inspection terminal Voltage regulator ambient
temperature °CVoltage V
Terminal "S"
−2014.2 − 15.4
20 13.9 − 14.9
60 13.4 − 14.6
80 13.1 − 14.5

CHARGING SYSTEM
ENGINE ELECTRICAL16-9
WAVEFORM CHECK USING AN OSCILLOSCOPEM1161001200124
MEASUREMENT METHODConnect the oscilloscope special patterns pick-up to
the alternator "B" terminal.
STANDARD WAVEFORM
Observation Conditions
NOTE:
The voltage waveform of the alternator "B" terminal
can undulate as shown in the illustration. This
waveform is produced when the regulator operates
according to fluctuations in the alternator load (current), and is normal for the alternator. In addition,
when the voltage waveform reaches an excessively
high value (approximately 2 V or higher at idle), it
often indicates an open circuit due to a brown fuse
between alternator "B" terminal and battery, but not a
defective alternator.
AK100002
Alternator
"B" terminalCH1
AC
Function Special pattern
Pattern height Variable
Variable knob Adjust while viewing the waveform.
Pattern selector Raster
Engine speed Curb idle speed
AKX00189
0.4 (V)
0.2
0
–0.2
–0.4 Voltage at
alternator
"B" terminal
Time
AG
AKX00190

CHARGING SYSTEM
ENGINE ELECTRICAL16-10
EXAMPLE OF ABNORMAL WAVEFORMS
NOTE: .
1. The size of the waveform patterns differs largely, depending on the adjustment of the variable knob on the
oscilloscope.
2. Identification of abnormal waveforms is easier when there is a large output current (regulator is not
operating). (Waveforms can be observed when the headlamps are illuminated.)
3. Check the conditions of the charging warning lamp (illuminated/not illuminated). Also, check the charging
system totally.
Abnormal waveform Problem cause
Example 1 Open diode
Example 2 Short in diode
AKX00191
AKX00192

CHARGING SYSTEM
ENGINE ELECTRICAL16-11
Example 3 Broken wire in
stator coil
Example 4 Short in stator
coil
Example 5
At this time, the charging warning lamp is illuminated.Open
supplementary
diode Abnormal waveform Problem cause
AKX00193
AKX00194
AKX00195

CHARGING SYSTEM
ENGINE ELECTRICAL16-12
ALTERNATOR ASSEMBLY
REMOVAL AND INSTALLATION <4G1>M1161001400548
REMOVAL SERVICE POINT
<<A>> ALTERNATOR ASSEMBLY
REMOVAL
Remove the alternator assembly from above the
vehicle.
Pre-removal Operation
•Under Cover Removal
•Drive Belt Removal (Refer to GROUP 11A - Crankshaft
Pulley P.11A-16).Post-installation Operation
•Drive Belt Installation (Refer to GROUP 11A - Crankshaft
Pulley P.11A-16).
•Drive Belt Tension Adjustment (Refer to GROUP 11A -
On-vehicle Service P.11A-7).
•Under Cover Installation
AC303729
1
2
4
3
44 ± 10 N·m
23 ± 2 N·m
24 ± 3 N·m12 ± 2 N·m
AB
Removal steps
1. Power steering pressure hose
clamp
2. Alternator connector and terminal3. Alternator adjusting brace
<<A>>4. Alternator assemblyRemoval steps (Continued)

CHARGING SYSTEM
ENGINE ELECTRICAL16-13
REMOVAL AND INSTALLATION <4G6>M1161001400559
Pre-removal Operation
•Under Cover Removal
•Strut Tower Bar Removal (Refer to GROUP 42 P.42-9).
•Drive Belt Removal (Refer to GROUP 11C - Crankshaft
Pulley P.11C-16).
•Air Cleaner Assembly Removal (Refer to GROUP 15
P.15-3).Post-installation Operation
•Air Cleaner Assembly Installation (Refer to GROUP 15
P.15-3).
•Drive Belt Installation (Refer to GROUP 11C - Crankshaft
Pulley P.11C-16).
•Strut Tower Bar Installation (Refer to GROUP 42 P.42-9).
•Drive Belt Tension Adjustment (Refer to GROUP 11C -
On-vehicle Service P.11C-7).
•Under Cover Installation
AC303826
1
2
318 ± 3 N·m
AB
Removal steps
1. Shift cable connection<<A>>2. shift cable and shift cable bracket
assembly
3. Vehicle speed sensor connectorRemoval steps (Continued)

CHARGING SYSTEM
ENGINE ELECTRICAL16-14
REMOVAL SERVICE POINT
<<A>> SHIFT CABLE AND SHIFT CABLE
BRACKET ASSEMBLY REMOVAL
Remove the shift cable bracket installation bolt with
the shift cable installed on the shift cable bracket,
and remove the shift cable and shift cable bracket
assembly from the transmission.
<<B>> ALTERNATOR ASSEMBLY
REMOVAL
After removing the alternator assembly installation
bolts and nut, move the alternator assembly to the
transmission side and remove the alternator
assembly upward the engine room through the
clearance between the transmission and the inlet
manifold.
AC303827
65
84
9 7
22 ± 4 N·m
23 ± 3 N·m
8.8 ± 1.0 N·m44 ± 10 N·m
AB
Removal steps
4. Battery wiring harness clamp
5. Engine oil pressure switch
connection
6. Alternator connector<<B>>7. Alternator assembly
8. Water pump pulley
9. Alternator braceRemoval steps (Continued)
AC302930AB
Alternator
assemnly

CHARGING SYSTEM
ENGINE ELECTRICAL16-15
DISASSEMBLY AND REASSEMBLYM1161001600166
AK202845
1
234
5
6
7
8910
11 12
1314
AE
4.4 ± 1.0 N·m
3.7 ± 0.7 N·m
189 ± 19 N·m
3.7 ± 0.7 N·m
Disassembly steps
<<A>>1. Front bracket assembly
<<B>>2. Alternator pulley
>>B<<3. Rotor
4. Rear bearing
5. Bearing retainer
6. Front bearing
7. Front bracket
<<C>>8. Stator
9. Plate
<<C>> >>A<<10. Regulator assembly
11 . B r u s h
12. Rubber packing
13. Rectifier
14. Rear bracketDisassembly steps (Continued)

CHARGING SYSTEM
ENGINE ELECTRICAL16-16
DISASSEMBLY SERVICE POINTS
<<A>>FRONT BRACKET ASSEMBLY
REMOVAL
CAUTION
Do not insert the screwdriver blades too deep.
Doing so could damage the stator coil.
Insert the blades of screwdrivers between the front
bracket assembly and stator core, and pry and
separate them with the screwdrivers.
<<B>>ALTERNATOR PULLEY REMOVAL
CAUTION
Perform operation carefully not to damage the
rotor.
Clamp the rotor in a vise with the pulley facing up to
remove the pulley.
<<C>>STATOR / REGULATOR ASSEMBLY
REMOVAL
CAUTION
•Use a 180 − 250 W soldering iron, and finish
unsoldering within four seconds. Diodes will
be damaged by heat if unsoldering time is too
long.
•Avoid applying undue force to the diode
leads.
1. Unsolder the stator leads from the main diode of
the rectifier assembly when the stator is removed.
2. When removing the rectifier assembly from the
regulator assembly, undo the soldered points on
the rectifier assembly.
REASSEMBLY SERVICE POINTS
>>A<<REGULATOR ASSEMBLY
INSTALLATION
After installing the regulator assembly, insert a piece
of wire through the hole in the rear bracket while
pressing the brush to keep the brush against
movement.
NOTE: Holding the brush with the wire facilities
installation of the rotor.
AK202718
AK202714
AK202778
Solder
Solder Rectifier
assembly
AB
AK202779
Wire
AB
AK202830
Rear bracket
Brush
Wire
AB