MITSUBISHI MONTERO 1991 Service Manual

Fig. 5: Charging System Wiring Schematic (Montero)
Courtesy of Mitsubishi Motor Sales of America.

Fig. 6: Charging System Wiring Schematic (Pickup & Ram-50)
Courtesy of Mitsubishi Motor Sales of America.

Fig. 7: Charging System Wiring Schematic (Precis)
Courtesy of Mitsubishi Motor Sales of America.

Fig. 8: Charging System Wiring Schematic (Stealth DOHC & 3000GT)
Courtesy of Mitsubishi Motor Sales of America.

Fig. 9: Charging System Wiring Schematic (Stealth SOHC)
Courtesy of Chrysler Motors.
ADJUSTMENTS

BELT ADJUSTMENT TABLE








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Application ( 1) New Belt Deflection: In. (mm)
Colt, Colt 200 & Summit ..................... .28-.35 (7.1-8.9)
Mirage
1.5L ...................................... .28-.35 (7.1-8.9)
1.6L ..................................... .35-.45 (8.9-11.4)
Colt Vista .................................. .28-.34 (7.1-8.6)
Eclipse & Galant
1.8L ..................................... .32-.43 (8.1-10.9)
2.0L ..................................... .35-.45 (8.9-11.4)
Montero ..................................... .22-.32 (5.6-8.1)
Pickup & Ram-50
2.4L ...................................... .28-.39 (7.1-9.9)
3.0L ...................................... .32-.39 (8.1-9.9)
Precis ...................................... .28-.32 (7.1-8.1)
Stealth & 3000GT
DOHC ...................................... .16-.22 (4.1-5.6)
SOHC ...................................... .24-.35 (6.1-8.9)
( 1) - Deflection measured with 22 lbs. (10 kg) pressure applied midway
on belt run.









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TROUBLE SHOOTING
NOTE: See TROUBLE SHOOTING - BASIC PROCEDURES article in the
GENERAL INFORMATION section.
TESTING (ON-VEHICLE)
ALTERNATOR TO BATTERY CONTINUITY TEST
NOTE: Check alternator wire harness connections and drive belt
tension and ensure battery is fully charged before
performing test.
1) Turn ignition switch to OFF position. Disconnect negative
battery cable. Remove output lead from alternator terminal "B". See
Fig. 10 . Install a 100-amp ammeter in series to terminal "B" and
disconnected output lead. Install positive lead of ammeter to terminal
"B" and negative lead to disconnected output wire.
Fig. 10: Identifying Alternator Terminals
Courtesy of Chrysler Motors.
2) Install a digital voltmeter between alternator terminal
"B" and positive battery terminal. Install positive voltmeter lead to

terminal "B" and negative lead to positive battery terminal. Reconnect
negative battery cable.
3) Start engine. Turn accessories on and adjust engine speed
until ammeter indicates 20 amps, and note voltmeter reading. If
voltmeter indicates .2 volt or less, system is okay.
4) If voltage is greater than .2 volt, wiring is defective
between alternator terminal "B", fusible link and battery positive
terminal. Disconnect negative battery cable, and remove test
equipment.
ALTERNATOR OUTPUT TEST
NOTE: During alternator output test, a slightly discharged battery
should be used as a fully charged battery may not allow full
alternator output.
1) Turn ignition switch to OFF position. Disconnect negative
battery cable. Disconnect alternator output wire from terminal "B".
Install positive lead of 100-amp ammeter to terminal "B" and negative
lead to disconnected output lead.
CAUTION: Tighten each connection securely as heavy current flow will
exist. DO NOT use clips on ammeter.
2) Connect positive voltmeter lead (0-20 volts) to alternato\
r
terminal "B" and negative lead to ground. Install tachometer, and
reconnect negative battery cable.
3) Ensure voltmeter indicates battery voltage. If no voltage
exists, an open circuit is present in wire between alternator terminal
"B" and battery negative terminal. Check grounds and fusible link.
4) Turn headlights on, and start engine. Set headlights at
high beam and heater switch on HIGH. Quickly accelerate engine speed
to 2500 RPM and note alternator output current registered on the
ammeter. Minimum output should be within specification. Refer to the
ALTERNATOR MINIMUM OUTPUT SPECIFICATIONS table.
NOTE: Output voltage changes with electrical load and temperature.
Ensure proper electrical load is applied while checking
output. Nominal output may not be obtained if alternator or
ambient temperature is excessive. Allow to cool, and recheck
output. Alternator output is stamped on metal plate attached
to alternator case.
5) If minimum output is not obtained and alternator wiring is
okay, repair alternator. Disconnect negative battery cable, and remove
test equipment.
REGULATED VOLTAGE TEST
NOTE: Ensure battery is fully charged and proper drive belt
tension exists.
1) Turn ignition switch to OFF position. Disconnect negative
battery cable. Install a digital voltmeter between alternator terminal
"S" and ground. See Fig. 10. Connect positive voltmeter lead to
terminal "S" of alternator. Connect negative voltmeter lead to ground.
2) Disconnect alternator output wire from terminal "B".
Install a 100-amp ammeter in series to terminal "B" and disconnected
output lead. Install positive lead of ammeter to terminal "B" and
negative lead to disconnected output wire. Install a tachometer, and
reconnect negative battery cable.
3) Turn ignition switch to ON position and ensure voltmeter
indicates battery voltage. If no voltage exists, an open circuit

exists in wire between alternator terminal "S" and positive battery
terminal or fusible link is blown.
4) Start engine. Ensure all lights and accessories are off.
Operate engine at 2500 RPM and read voltmeter when alternator output
current drops to 10 amps or less. Voltage regulator is okay if voltage
output is within specification. See REGULATOR VOLTAGE SPECIFICATIONS
table.
BENCH TESTING
RECTIFIER ASSEMBLY
1) Using ohmmeter, check for continuity between both diodes
and stator coil lead connection. See Fig. 11. Reverse leads. If
continuity exists in both directions, diode is shorted. Replace
rectifier assembly.
2) To check entire diode assembly, use an ohmmeter to check
for continuity between both ends of each diode. See Fig. 11. Switch
ohmmeter leads. Continuity should exist in one direction, but not
other. If no continuity exists or continuity exists in both
directions, diode is defective. Replace rectifier assembly.
Fig. 11: Testing Rectifier Assembly
Courtesy of Mitsubishi Motor Sales of America.
ROTOR

1) Check continuity across rotor slip rings. Resistance
should be within specification. See ROTOR RESISTANCE SPECIFICATIONS
table. Replace rotor if no continuity exists or resistance is not
within specification.
2) Check continuity between individual slip rings and rotor
shaft. If continuity exists, rotor coil or slip ring is grounded.
Replace rotor.
STATOR
Ensure no continuity exists between stator coil leads and
stator core. Check continuity between leads of stator coil. If no
continuity exists between coil leads, replace stator.
OVERHAUL
Replace brushes if worn to limit line. Limit line is line
closest to rotor contact end of brush. Brushes can be retained in
brush holder while installing rotor by inserting wire into back of
rear housing.
Fig. 12: Exploded View of Typical Mitsubishi Alternator
Courtesy of Mitsubishi Motor Sales of America.
SPECIFICATIONS
ALTERNATOR MINIMUM OUTPUT SPECIFICATIONS TABLE








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Application Amps

Colt, Colt 200, Galant, Montero, Precis & Summit ......... 52.5
Colt Vista ................................................. 45
Eclipse
A/T & M/T Turbo ........................................ 52.5
M/T Non-Turbo .......................................... 45.5
Mirage
1.5L & 1.6L A/T ........................................ 52.5
1.6L M/T ............................................... 45.5
Pickup & Ram-50
2.4L ..................................................... 28
2.4L (Optional - Ram-50) ................................. 42
3.0L ................................................... 45.5
Stealth & 3000GT
DOHC ..................................................... 77
SOHC ..................................................... 63









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REGULATOR VOLTAGE SPECIFICATIONS TABLE








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Ambient Temperature Voltage
-4
F (-20C) ........................................ 14.2-15.4
68F (20C) ......................................... 13.9-14.9
140F (60C) ........................................ 13.4-14.6
176F (80C) ........................................ 13.1-14.5








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ROTOR RESISTANCE SPECIFICATIONS TABLE








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Application Ohms
Colt, Colt 200, Mirage, Precis & Summit ................... 3.1
Colt Vista ................................................ 4.3
Eclipse, Galant, Montero, Pickup,
Ram-50, Stealth & 3000GT ............................. 3.0-5.0









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