Charging MITSUBISHI MONTERO 1987 1.G Workshop Manual

Service Manual
MONTERO
1987 : Volume 2
FOREWORD
This Service Manual has been prepared with the
latest service information available at the time of
publication. It is subdivided into various group
categories and each section contains diagnosis,
disassembly, repair, and installation procedures
along with complete specifications and tightening
references. Use of this manual will aid in properly
performing any servicing necessary to maintain or
restore the high levels of performance and reliability
designed into these outstanding vehicles.
WE SUPPORT
VOLUNTARY TECHNICIAN
CERTIFICATION THROUGH
MITSUBISHI MOTOR SALES OF AMERICA. Inc.
Mitsubishi Motors corporation reserves the right to make changes in
design or to make additions to or improvements in its products without
imposing any obligations upon itself to install them on its products
previously manufactured.
I
GROUP/SECTION INDEX ‘kme-.
INTRODUCTION ..............................
Electrical ...........................................
Electrical System Parts
Location .........................................
Relays, Control Units, Sensors,
Fuses, Groundings
Inspection of Harness
Connector ......................................
Wiring Harness .............................
Charging System ..........................
Starting System ............................
Ignition System .............................
Meters and Gauges ......................
Lighting System .............................
Wiper and Washer System ..........
Horn ...............................................
Accessory ......................................
Audio System ................................
Back Door Window Defogger ......
Automatic Free-wheeling Hub
Indicator System ..........................
Heaters and Air-conditioning .........
Heaters ..........................................
Air-conditioning ............................
**, For Engine Chassis & Body refer to
0 1986 Mitsubishi Motors Corporation Printed in Japan

8-1
ELECTRICAL
CONTENTS
NOBAA-
ACCESSORY ......................................................
188
Cigarette Lighter ............................................
,190
Clock ...............................................................
,191
AUDIO SYSTEM ................................................
.192
AUTOMATIC FREE-WHEELING HUB
INDICATOR SYSTEM ........................................
208
Automatic Free-wheeling Hub
Indicator Control Unit
..................................... ,216
Pulse Generator ..............................................
215
BACK DOOR WINDOW DEFOGGER
................ .203
Defogger switch ............................................
,206
Printed Heater Lines
...................................... ,207
CHARGING SYSTEM .........................................
71
Alternator ........................................................
83
Service Adjustment Procedures
..................... 77
Battery Charging ........................................
82
Inspection of Battery ..................................
81
Output Current Test ...................................
78
Regulated Voltage Test ..............................
79
Voltage Drop Test of Alternator Output
Wire ............................................................
77
ELECTRICAL SYSTEM PARTS LOCATION
...... 2
Diode ...............................................................
5
Fusible Link and Fuse
..................................... 6
Grounding .......................................................
7
Relay and Control Unit ....................................
2
Sensor .............................................................
4
HORN ..................................................................
184
Horn Switch
.................................................... 187
IGNITION SYSTEM ............................................
105
Ignition Switch
................................................ 122
Ignition System ...............................................
1 14
Service Adjustment Procedures
.................... .l 1 1
Checking Ignition System
..........................
11 1
Checking Ignition Timing
...........................
11 1
Spark Plug Cable Test
................................
1 12
Spark Plug Test
.......................................... 1 12 INSPECTION OF HARNESS CONNECTOR ...... 9
Check for Improper Engagement of
Terminal .......................................................... 9
Continuity and Voltage Test for Connector .... 9
Engaging and Disengaging of Connector
Terminal ..........................................................
9
LIGHTING SYSTEM ........................................... 143
Column Switch
................................ .
.............. .I59
Dimmer Control Switch
................................. .I62
Hazard Warning Switch
................................. .I61
Headlight ........................................................ ,158
Service Adjustment Procedures
.................... .I57
Headlight Aiming .......................................
157
METERS AND GAUGES .................................... 123
Service Adjustment Procedures
.................... .I30
Fuel Gauge Simple Test ................................. .I31
Fuel Gauge Unit Inspection ........................... .I31
Oil Pressure Gauge Simple Test
.................... .I32
Oil Pressure Gauge Unit Simple Test
............ ,132
Speedometer Inspection
............................... .I30
Tachometer Inspection .................................. ,130
Voltage Meter Simple Test
............................ .I33
Water Temperature Gauge Simple Test
....... ..I3 1
Water Temperature Gauge Unit Inspection
. ..I3 2
STARTING SYSTEM .......................................... 91
Starter Motor ............ ....................................... 97
WIPER AND WASHER SYSTEM
....................... .163
WIRING HARNESS ............................................ 13
Centralized Junction ....................................... 69
Circuit Diagram ............................................... 34
Configuration Diagram .................................... 27
How to Read Wiring Diagrams ....................... 20
Troubleshooting .............................................. 13

WIRING HARNESS - Charging Circuit 8-37
3 CHARGING CIRCUIT
S‘
Main
fusible ’ L m
link
Battery A-02
, 3
Alternator
El A-48 A-23 Sub fusible link
(IGN - SW)
I
3
cl
Ignition switch
.n
1 Comornatron meter
Remark
For information concerning the ground points (example:
q ),
refer to P.8-7.
3
c:
-22
t 3
c!J I
To turn signal flasher
unit [Refer to P.8-49.1
J 3
a
I
6
m ‘I 81
Multi-
purpose
fuse
37W605
Wiring color code
B: Black Br: Brown G: Green Gr: Gray L: Blue Lg: Light green
LI: Light blue 0: Orange P: Pink R: Red Y: Yellow W: White . / STB Revision

CHARGING SYSTEM - General Information 8-71
CHARGING SYSTEM
GENERAL INFORMATION
NOBEMD
The charging system comprises battery, alternator with regulator, charging indicator light and wire.
The alternator has 6 built in rectifiers (3 positive and 3 negative), which rectify alternating current to direct current.
Accordingly, the alternator terminal B is D/C. Furthermore the alternator regulates the charge voltage through the
use of battery voltage detection system.
The main parts of the alternator are: rotor, stator, rectifier, condenser, brush, bearing, drive belt pulley and a
brush holder with built in electronic voltage regulator.
:--\;-----------I ;
I.C. regulator
I
-A I.C. alternator -y
Brush
heat -sink assembly Drive
-belt
pulley
Rotor light
6EL239
Stator 6EN246 6EN211
1 STB Revision

8-72 CHARGING SYSTEM - General Information
Test indicator
MAINTENANCE FREE TYPE BATTERY
The maintenace-free battery is, as the name implies, totally
maintenance free and has no removable battery cell caps.
Water never needs to be added to the maintenace-free
battery.
The battery is completely sealed, except for small vent holes in
the cover, These vent holes allow what small amount of
gasses are produced in the battery to escape. The special
chemical composition inside the battery reduces the produc-
tion of gas to an extremely small amount at normal charging
voltages. The battery contains a visual test indicator which
indicates the condition of the battery.
( ST6 Revision

CHARGING SYSTEM -Specifications
SPECIFICATIONS
GENERAL SPECIFICATIONS
ALTERNATOR NOOEB-B
Type
Model No.
Part No.
Rated output
VIA
Voltage regulator Items Specifications
~--
Battery voltage sensing
A2T03477
MD1 10318
12150
Electronic built-in type
BAlTERY
Items
Type
1
Ampere hours (5 HR) Ah
Cranking rating [at - 178°C (O”F)] A
Reserve capacity min. Specifications
55824R (S)-MF
36
420
75
NOTES
1. CRANKING RATING is the current a battery can deliver for 30 seconds and maintain a terminal voltage of 7.2 or
greater at a specified temperature.
2. RESERVE CAPACITY RATING is the amount of time a battery can deliver 25 A and maintain a minimum terminal
voltage of 10.5 at 26.7”C (80°F).
SERVICE SPECIFICATIONS NOBEC-
Items
Standard values
Regulated voltage V
Ambient temp. at voltage regulator
- 20°C ( - 4°F)
20°C (68°F)
60°C (140°F)
80°C (176°F)
Slip ring O.D. mm (in.)
Field coil resistance R
Limit
Output current A
Slip ring O.D. mm (in.) 14.2-15.4
13.9-14.9
13.4-14.6
13.1-14.5
23 (.906)
3.1
Min. 35
22.2 (.874) Specifications
[ STB Revision

8-74 CHARGING SYSTEM -Specifications
TORQUE SPECIFICATIONS
items Nm ft.lbs.
__-
Alternator brace bolt
12-15
9-l 1
Alternator support bolt nut
20-22
14-16
High pressure hose nut
20-25
14-18
Low hose nut
pressure 30-35
22-25
.
1 STB Revision

CHARGING SYSTEM -Troubleshooting 8-75
TROUBLESHOOTING
NOBEH-
Symptom Probable cause
Remedy Reference
we
Charging warning in- Fuse blown
dicator does not light
with ignition switch Light burned out
“ON” and engine off. 1
1 Wiring connection loose Check fuses
Replace light
Tighten loose connections 8-70
-
-
Charging warning in-
dicator does not go
out with engine
running
(Battery requires fre-
quent recharging)
L
t
Run-down battery
c
Electronic voltage regulator faulty
Drive belt loose or worn
Battery cables loose, corroded or worn
Fuse blown
Fusible link blown
Electronic voltage regulator or alternator
faulty
Wiring faulty
Drive belt loose or worn
Wiring connection loose or open circuit
Fusible link blown Replace voltage regulator
Adjust tension or replace drive
belt
Repair or replace cables
Check fuses
Replace fusible link
Test alternator
Repair wiring
Adjust tension or replace drive
belt
Tighten loose connection or
repair wiring
Replace fusible link 8-79
Refer to
GROUPS.
8-8 1
8-70
8-69
8-77
8-79
-
Refer to
GROUP 9.
-
8-69
Poor grounding 1 Repair
I-
I I I Electronic voltage regulator or alternator
faulty Test alternator 8-77
8-79
Overcharge Decrease in life of battery
Replace battery
8-81 I
Electronic voltage regulator faulty Replace voltage regulator 8-79
STB Revision

8-76 CHARGING SYSTEM - Circuit Diagram
3 CHARGING CIRCUIT
Battery Ignition switch
OFF
Main
m fusible ’ L
link
A-02
fl.3-Br 1~5~~
, A-23 Sub fusible link
(IGN . SW)
IAM IG ] c-55
3
3
A m
A
To turn signal flasher
unit [Refer to P.8-49.1 Multi-
n, Irnn4P
ComSeter
Remark
For information concerning the ground points (example:
q ),
refer to P.8-7. 37W605
Wiring color code
B: Black Br: Brown G: Green Gr: Gray L: Blue Lg: Light green
LI: Light blue 0: Orange P: Pink R: Red Y: Yellow W: White
1 STB Revision

CHARGING SYSTEM - Service Adjustment Procedures 8-77
SERVICE ADJUSTMENT PROCEDUREswmAB
lEL15I
INSPECTION OF THE CHARGING SYSTEM
VOLTAGE DROP TEST OF ALTERNATOR OUTPUT WIRE
This test judges whether or not the wiring (including the fusible
link) between the alternator B terminal and the battery (+) terminal
is sound by the voltage drop method.
Preparation
(1) Turn the ignition switch to “OFF”.
(2) Disconnect the battery ground cable.
(3) Disconnect the alternator output lead from the alternator “B”
terminal.
(4) Connect a DC ammeter (0 to 100 A) in series to the “B”
terminal and the disconnected output lead. Connect the (+)
lead of the ammeter to the “B” terminal and the (-) lead to
the disconnected output wire.
NOTE
Use of a clamp type ammeter that can measure current with-
out disconnecting the harness is preferred. The reason is that
when checking a vehicles that has a low output current due to
poor connection of the alternator “B” terminal, such poor con-
nection is corrected as the “B” terminal is loosened and a test
ammeter is connected in its place and as a result, causes for
the trouble may not be determined.
(5) Connect a digital voltmeter between the alternator “B” termi-
nal and battery (+) terminal. Connect the (+) lead wire of the
voltmeter to the “B” terminal and the (-) lead wire to the
battery (+) terminal.
(6) Connect the battery ground cable.
(7) Leave the hood open.
Test
(1) Start the engine.
(2) Turn on or off the headlights and small lights and adjust the
engine speed so that the ammeter reads 20 A and read off the
voltmeter indication under this condition.
Result
(1) It is okay if the voltmeter indicates the standard value. ’
Standard value : 0.2 V max.
(2) If the voltmeter indicates a value that is larger than the stan-
dard value, poor wiring is suspected, in which case check the
wiring from the alternator “B” terminal to fusible link to bat-
tery (+) terminal. Check for loose connection, color change
due to overheated harness, etc. and correct them before test-
ing again.
(3) Upon completion of the test, set the engine speed at idle. Turn
off the lights and turn off the ignition switch.
(4) Disconnect the battery ground cable.
(5) Disconnect the ammeter and voltmeter that have been con-
nected for the test purpose.
(6) Connect the alternator output wire to the alternator “B” ter-
minal.
(7) Connect the battery ground cable.
( STB Revision