Mitsubishi Car 1999-05

Alternator

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Diagnosis & Testing



Alternator Load Test
  1. With the engine running, turn on the blower motor and the high beams (or other electrical accessories to place a load on the charging system).
  2.  
  3. Increase and hold engine speed to 2000 rpm.
  4.  
  5. Measure the voltage reading at the battery.
  6.  
  7. The voltage should increase at least 0.5 volts from the voltage test. If the voltage does not meet specifications, the charging system is malfunctioning.
  8.  


NOTE
Usually under and overcharging is caused by a defective alternator, or its related parts (regulator), and replacement will fix the problem; however, faulty wiring and other problems can cause the charging system to malfunction. Many automotive parts stores have alternator bench testers available for use by customers. An alternator bench test is the most definitive way to determine the condition of your alternator.

  1. With the engine running, turn on the blower motor and the high beams (or other electrical accessories to place a load on the charging system).
  2.  
  3. Increase and hold engine speed to 2000 rpm.
  4.  
  5. Measure the voltage reading at the battery.
  6.  
  7. The voltage should increase at least 0.5 volts from the voltage test. If the voltage does not meet specifications, the charging system is malfunctioning.
    NOTE
    Usually under and overcharging is caused by a defective alternator, or its related parts (regulator), and replacement will fix the problem; however, faulty wiring and other problems can cause the charging system to malfunction. Further testing, which is not covered by this book, will reveal the exact component failure. Many automotive parts stores have alternator bench testers available for use by customers. An alternator bench test is the most definitive way to determine the condition of your alternator.

  8.  

Alternator No-Load Test
  1. Connect a tachometer to the engine.
  2.  


CAUTION
Ensure that the transmission is in Park and the emergency brake is set. Blocking a wheel is optional and an added safety measure.

  1. Turn off all electrical loads (radio, blower motor, wipers, etc.)
  2.  
  3. Start the engine and increase engine speed to approximately 1500 rpm.
  4.  
  5. Measure the voltage reading at the battery with the engine holding a steady 1500 rpm. Voltage should have raised at least 0.5 volts, but no more than 2.5 volts.
  6.  
  7. If the voltage does not go up more than 0.5 volts, the alternator is not charging. If the voltage goes up more than 2.5 volts, the alternator is overcharging.
  8.  


NOTE
Usually under and overcharging is caused by a defective alternator, or its related parts (regulator), and replacement will fix the problem; however, faulty wiring and other problems can cause the charging system to malfunction. Many automotive parts stores have alternator bench testers available for use by customers. An alternator bench test is the most definitive way to determine the condition of your alternator.

  1. If the voltage is within specifications, proceed to the next test.
  2.  

  1. Connect a tachometer to the engine.
    CAUTION
    Ensure that the transmission is in Park and the emergency brake is set. Blocking a wheel is optional and an added safety measure.

  2.  
  3. Turn off all electrical loads (radio, blower motor, wipers, etc.)
  4.  
  5. Start the engine and increase engine speed to approximately 1500 rpm.
  6.  
  7. Measure the voltage reading at the battery with the engine holding a steady 1500 rpm. Voltage should have raised at least 0.5 volts, but no more than 2.5 volts.
  8.  
  9. If the voltage does not go up more than 0.5 volts, the alternator is not charging. If the voltage goes up more than 2.5 volts, the alternator is overcharging.
    NOTE
    Usually under and overcharging is caused by a defective alternator, or its related parts (regulator), and replacement will fix the problem; however, faulty wiring and other problems can cause the charging system to malfunction. Further testing, which is not covered by this book, will reveal the exact component failure. Many automotive parts stores have alternator bench testers available for use by customers. An alternator bench test is the most definitive way to determine the condition of your alternator.

  10.  
  11. If the voltage is within specifications, proceed to the next test.
  12.  

Voltage Test
  1. Make sure the engine is OFF , and turn the headlights on for 15-20 seconds to remove any surface charge from the battery.
  2.  
  3. Using a DVOM set to volts DC, probe across the battery terminals.
  4.  
  5. Measure the battery voltage.
  6.  
  7. Write down the voltage reading and proceed to the next test.
  8.  

  1. Make sure the engine is OFF , and turn the headlights on for 15-20 seconds to remove any surface charge from the battery.
  2.  
  3. Using a DVOM set to volts DC, probe across the battery terminals.
  4.  
  5. Measure the battery voltage.
  6.  
  7. Write down the voltage reading and proceed to the next test.
  8.  

Installation



  1. Position the alternator on the lower mounting fixture and install the lower mounting bolt and nut. Tighten nut just enough to allow for movement of the alternator.
  2.  
  3. On the 1.6L engine, lower the radiator and reinstall the upper attaching bolts.
  4.  
  5. On the 1.6L engine, install the battery, windshield washer reservoir and battery tray.
  6.  
  7. Install or connect the following:

    Alternator upper bracket/brace and connect the alternator electrical harness
     
    Water pump pulleys
     
    Drive belts and adjust to the proper tension
     

  8.  
  9. On turbocharged Galant models, install the air intake hose.
  10.  
  11. Install or connect the following:

    Left side cover panel under the vehicle as required
     
    Negative battery cable and check for proper operation
     

  12.  

Precautions



Several precautions must be observed when performing work on alternator equipment.



If the battery is removed for any reason, make sure that it is reconnected with the correct polarity. Reversing the battery connections may result in damage to the one-way rectifiers.
 
Never operate the alternator with the main circuit broken. Make sure that the battery, alternator, and regulator leads are not disconnected while the engine is running.
 
Never attempt to polarize an alternator.
 
When charging a battery that is installed in the vehicle, disconnect the negative battery cable.
 
When utilizing a booster battery as a starting aid, always connect it in parallel; negative to negative, and positive to positive.
 
When arc (electric) welding is to be performed on any part of the vehicle, disconnect the negative battery cable and alternator leads.
 
Never unplug the PCM while the engine is running or with the ignition in the ON position. Severe and expensive damage may result within the solid state equipment.
 

Removal & Installation



1.5L, 1.8L, 2.0L & 2.4L Engines


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Fig. Detach the regulator connector from the alternator



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Fig. Remove the nut retaining the battery cable to the alternator . . .



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Fig. . . . then remove the battery cable from the alternator



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Fig. Remove the nut retaining the wire harness to the alternator, and remove the harness from the alternator



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Fig. Remove the nut for the pivot bolt on the rear of the alternator . . .



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Fig. . . . then remove the pivot bolt from the alternator



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Fig. Remove the alternator adjusting bolt . . .



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Fig. . . . then remove the alternator from the vehicle

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the left side cover panel under the vehicle.
  4.  
  5. Remove the drive belts.
  6.  
  7. Remove the water pump pulleys.
  8.  
  9. Remove the alternator upper bracket/brace.
  10.  
  11. Detach the alternator wiring connectors.
  12.  
  13. Remove the alternator mounting bolts and remove the alternator.
  14.  

To install:

  1. Position the alternator on the lower mounting fixture and install the lower mounting bolt and nut. Tighten nut just enough to allow for movement of the alternator.
  2.  
  3. Install the alternator upper bracket/brace and connect the alternator electrical harness.
  4.  
  5. Install the water pump pulleys.
  6.  
  7. Install the drive belts and adjust to the proper tension.
  8.  
  9. Install the left side cover panel under the vehicle as required.
  10.  
  11. Connect the negative battery cable and check for proper operation.
  12.  

2.0L DOHC Turbo Engine
  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the oil dipstick and tube assembly.
  6.  
  7. Disconnect the fuel pressure solenoid connector.
  8.  
  9. Disconnect the knock sensor connector.
  10.  
  11. Disconnect the evaporative emissions purge solenoid connector.
  12.  
  13. Disconnect the ground cable connection.
  14.  
  15. Remove the fuel injectors.
  16.  
  17. Remove the accessory drive belt.
  18.  
  19. Disconnect the alternator wiring harness.
  20.  
  21. Remove engine mounting bolt.
  22.  
  23. Raise the engine slightly with a floor jack and remove the alternator from the vehicle.
  24.  

  1. Install the alternator onto the engine and connect the wiring harness.
  2.  
  3. Install the engine mounting bolt and tighten bolt to 73 ft. lbs. (98 Nm).
  4.  
  5. Install the accessory drive belt.
  6.  
  7. Install the fuel injectors.
  8.  
  9. Connect the ground cable connection.
  10.  
  11. Connect the evaporative emissions purge solenoid connector.
  12.  
  13. Connect the knock sensor connector.
  14.  
  15. Connect the fuel pressure solenoid connector.
  16.  
  17. Install the oil dipstick and tube assembly.
  18.  
  19. Connect the negative battery cable and check the charging system for proper operation.
  20.  

2.0L SOHC Engine
  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Drive belts
     
    Power steering hose clamp
     
    Alternator brace
     
    Alternator electrical connector
     
    Engine mount, on vehicles with Anti-lock Brake Systems (ABS)
     
    Alternator, tilting the engine as necessary
     

  4.  


    Click image to see an enlarged view

    Fig. Exploded view of the alternator and related components-Lancer with 2.0L engine


  1. Install or connect the following:

    Alternator
     
    Engine mount, if removed
     
    Alternator connector
     
    Alternator brace
     
    Power steering hose clamp
     
    Drive belts
     
    Negative battery cable
     

  2.  
  3. Adjust drive belts.
  4.  

3.0L DOHC Engines


Click image to see an enlarged view

Fig. Alternator mounting-3.0L DOHC engine

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the headlamp washer reservoir tank.
  4.  
  5. Remove the condenser fan and upper radiator insulator.
  6.  
  7. Loosen the tensioner pulley and remove the alternator drive belt.
  8.  
  9. Remove the alternator upper and lower mounting bolts.
  10.  
  11. Remove the alternator support bracket mounting bolts.
  12.  
  13. Remove the alternator support bracket from the vehicle.
  14.  
  15. Disconnect the alternator wiring harness.
  16.  
  17. Remove the alternator from the vehicle.
  18.  

To install:

  1. Install the alternator to the vehicle and connect the wiring harness.
  2.  
  3. Install the alternator support bracket to the vehicle and tighten the bracket mounting bolts to specifications.
  4.  
  5. Position the alternator on the mounting bracket. Install and tighten the mounting bolt and nut to 17 ft. lbs. (24 Nm).
  6.  
  7. Reinstall the drive belt and adjust the tensioner until the proper belt tension is achieved.
  8.  
  9. Install the upper radiator insulator and condenser fan.
  10.  
  11. Install the headlamp washer reservoir tank.
  12.  
  13. Connect the negative battery cable and check the charging system for proper operation.
  14.  



Click image to see an enlarged view

Fig. Alternator mounting-3.0L DOHC engine

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the headlamp washer reservoir tank.
  4.  
  5. Remove the condenser fan and upper radiator insulator.
  6.  
  7. Loosen the tensioner pulley and remove the alternator drive belt.
  8.  
  9. Remove the alternator upper and lower mounting bolts.
  10.  
  11. Remove the alternator support bracket mounting bolts.
  12.  
  13. Remove the alternator support bracket from the vehicle.
  14.  
  15. Disconnect the alternator wiring harness.
  16.  
  17. Remove the alternator from the vehicle.
  18.  

To install:

  1. Install the alternator to the vehicle and connect the wiring harness.
  2.  
  3. Install the alternator support bracket to the vehicle and tighten the bracket mounting bolts to specifications.
  4.  
  5. Position the alternator on the mounting bracket. Install and tighten the mounting bolt and nut to 17 ft. lbs. (24 Nm).
  6.  
  7. Reinstall the drive belt and adjust the tensioner until the proper belt tension is achieved.
  8.  
  9. Install the upper radiator insulator and condenser fan.
  10.  
  11. Install the headlamp washer reservoir tank.
  12.  
  13. Connect the negative battery cable and check the charging system for proper operation.
  14.  

3.0L SOHC & 3.5L Engines


Click image to see an enlarged view

Fig. Alternator mounting-3.0L SOHC engine



Click image to see an enlarged view

Fig. Alternator mounting -3.5L engine

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect and remove the air intake hose.
  4.  
  5. Loosen the tensioner pulley and remove the alternator drive belt.
  6.  
  7. On California models, remove the rear bank converter assembly.
  8.  
  9. Remove the engine roll stopper stay bracket assembly.
  10.  
  11. On the 3.0L SOHC engine, disconnect the EGR temperature sensor wire and remove the EGR pipe assembly.
  12.  
  13. On the 3.0L SOHC engine, remove the intake plenum stay bracket assembly.
  14.  
  15. Detach the alternator wiring harness connectors.
  16.  
  17. Remove the alternator upper and lower mounting bolts.
  18.  
  19. From beneath the vehicle, remove the alternator.
  20.  

To install:

  1. Position the alternator on the lower mounting fixture. Install and tighten the mounting bolt and nut to 14-18 ft. lbs. (20-25 Nm).
  2.  
  3. Connect the alternator wiring harness.
  4.  
  5. On the 3.0L SOHC engine, install the intake plenum stay bracket and tighten the mounting bolt to 13 ft. lbs. (18 Nm).
  6.  
  7. On the 3.0L SOHC engine, install the EGR pipe and tighten the fitting connections to 43 ft. lbs. (60 Nm).
  8.  
  9. On the 3.0L SOHC engine, connect the EGR temperature sensor wire.
  10.  
  11. Connect the engine roll stopper stay and tighten the mounting bolt to 35 ft. lbs. (45 Nm) and the nut to 36-43 ft. lbs. (50-60 Nm).
  12.  
  13. Install the rear converter assembly, if removed.
  14.  
  15. Reinstall the drive belt and adjust the tensioner until the proper belt tension is achieved.
  16.  
  17. Connect the air intake hose.
  18.  
  19. Connect the negative battery cable and check the charging system for proper operation.
  20.  



Click image to see an enlarged view

Fig. Alternator mounting-3.0L SOHC engine



Click image to see an enlarged view

Fig. Alternator mounting -3.5L engine

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect and remove the air intake hose.
  4.  
  5. Loosen the tensioner pulley and remove the alternator drive belt.
  6.  
  7. On California models, remove the rear bank converter assembly.
  8.  
  9. Remove the engine roll stopper stay bracket assembly.
  10.  
  11. On the 3.0L SOHC engine, disconnect the EGR temperature sensor wire and remove the EGR pipe assembly.
  12.  
  13. On the 3.0L SOHC engine, remove the intake plenum stay bracket assembly.
  14.  
  15. Detach the alternator wiring harness connectors.
  16.  
  17. Remove the alternator upper and lower mounting bolts.
  18.  
  19. From beneath the vehicle, remove the alternator.
  20.  

To install:

  1. Position the alternator on the lower mounting fixture. Install and tighten the mounting bolt and nut to 14-18 ft. lbs. (20-25 Nm).
  2.  
  3. Connect the alternator wiring harness.
  4.  
  5. On the 3.0L SOHC engine, install the intake plenum stay bracket and tighten the mounting bolt to 13 ft. lbs. (18 Nm).
  6.  
  7. On the 3.0L SOHC engine, install the EGR pipe and tighten the fitting connections to 43 ft. lbs. (60 Nm).
  8.  
  9. On the 3.0L SOHC engine, connect the EGR temperature sensor wire.
  10.  
  11. Connect the engine roll stopper stay and tighten the mounting bolt to 35 ft. lbs. (45 Nm) and the nut to 36-43 ft. lbs. (50-60 Nm).
  12.  
  13. Install the rear converter assembly, if removed.
  14.  
  15. Reinstall the drive belt and adjust the tensioner until the proper belt tension is achieved.
  16.  
  17. Connect the air intake hose.
  18.  
  19. Connect the negative battery cable and check the charging system for proper operation.
  20.  

3.8L Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the necessary components in order to gain access to the alternator assembly.
  4.  
  5. Disconnect the alternator electrical connections.
  6.  
  7. Remove the alternator mounting bolts.
  8.  
  9. Remove the alternator from the vehicle.
    NOTE
    On some vehicles it may be easier to remove the alternator from underneath of the vehicle.

  10.  

To install:

  1. Position the alternator assembly to its mounting.
  2.  
  3. Install the retaining bolts.
  4.  
  5. Connect the electrical connectors.
  6.  
  7. Continue the installation in the reverse order of the removal procedure.
  8.  

 
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