Mitsubishi Montero, Sport 1998-06

Alternator

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Diagnosis & Testing



Visually check the alternator wiring and listen for abnormal noises. Check that the wiring is in good condition. Check that there is no abnormal noise from the alternator while the engine is running.

Removal



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Under cover
     
    Air cleaner assembly, ducts and air intake hose
     
    Drive belt(s)
     
    Wires
     
    Mounting bracket, if equipped
     
    Alternator
     

  4.  

To install:

  1. Install or connect the following:

    Alternator. On the 2.4L torque the through-bolt to 14-18 ft. lbs. (20-25 Nm) and the bracket bolt to 106-133 inch lbs. (12-15 Nm). On the 3.0L and 3.5L torque the through-bolt to 38 ft. lbs. (52 Nm) and the mounting bolt to 16 ft. lbs. (22 Nm).
     
    Mounting bracket, if equipped. Torque the bolt to 14-18 ft. lbs. (20-25 Nm).
     
    Wires. Torque the nut to 124 inch lbs. (14 Nm).
     
    Drive belt(s)
     
    Air cleaner assembly, ducts and air intake hose
     
    Under cover
     
    Negative battery cable

    Click image to see an enlarged view

    Fig. Alternator mounting and related components

     

  2.  

Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Under cover
     
    Air cleaner assembly, ducts and air intake hose
     
    Drive belt(s)
     
    Wires
     
    Mounting bracket, if equipped
     
    Alternator
     

  4.  

To install:

  1. Install or connect the following:

    Alternator. Torque the through-bolt to 38 ft. lbs. (52 Nm) and the mounting bolt to 16 ft. lbs. (22 Nm).
     
    Mounting bracket, if equipped. Torque the bolt to 14-18 ft. lbs. (20-25 Nm).
     
    Wires. Torque the nut to 124 inch lbs. (14 Nm).
     
    Drive belt(s)
     
    Air cleaner assembly, ducts and air intake hose
     
    Under cover
     
    Negative battery cable
     

  2.  


    Click image to see an enlarged view

    Fig. Alternator mounting and related components


3.0L 12 Valve

Before servicing the vehicle, refer to the Precautions Section.

Remove the following:

  1. Drive belt
  2.  
  3. Cooling fan
  4.  
  5. Fan pulley
  6.  
  7. Idler puller
  8.  
  9. Tensioner pulley
  10.  
  11. Adjusting bolt
  12.  
  13. Adjusting stud
  14.  
  15. Tensioner bracket
  16.  
  17. Cooling fan bracket assembly
  18.  
  19. Tensioner bracket stay
  20.  
  21. Generator brace
  22.  
  23. Generator

    Click image to see an enlarged view

    Fig. Removing and installing the generator

  24.  

To install

Reverse the removal procedure.

3.5L Engines

Before servicing the vehicle, refer to the Precautions Section.

Remove the following:

  1. Cooling fan
  2.  
  3. Cooling fan clutch
  4.  
  5. Drive belt
  6.  
  7. Cooling fan pulley
  8.  
  9. Cooling fan bracket
  10.  
  11. Drive belt tensioner
  12.  
  13. Timing indicator
  14.  
  15. Generator

    Click image to see an enlarged view

    Fig. Removing and installing the generator (3.5L 1996)

  16.  

To install:

Reverse removal procedure. Use a belt tension gauge to check belt tension, or check deflection by applying 22 lbs. pressure. Tension for a new belt should be 143-187 lbs. The tension for a used belt should be 99-121 lbs. Deflection for a new belt between the cooling fan and the crankshaft pulley should be .16-.20 inch. The deflection for a used belt between the cooling fan and the crankshaft pulley should be .22-.26 inch. Deflection for a new belt between the cooling fan and generator should be .22-.30 inch. The deflection for a used belt between the cooling fan pulley and generator should be .31-.35 inch.

All Others

On some vehicles, the alternator is mounted very low on the engine. It may be necessary to remove the gravel shield and work from beneath the vehicle in order to gain access to the alternator. Replacing the alternator while the engine is cold is recommended.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Under cover
     
    Air cleaner assembly, ducts and air intake hose
     
    Drive belt(s)
     
    Wires
     
    Mounting bracket, if equipped
     
    Alternator
     

  4.  

To install:

  1. Install or connect the following:

    Alternator. Torque the through-bolt to 32-40 ft. lbs. (44-54 Nm). Torque the other r retaining bolt to 14-18 ft. lbs. (20-25 Nm).
     
    Mounting bracket, if equipped. Torque the bolt to 14-18 ft. lbs. (20-25 Nm).
     
    Wires. Torque the nut to 98-150 inch lbs. (11-17 Nm).
     
    Drive belt(s)
     
    Air cleaner assembly, ducts and air intake hose
     
    Under cover
     
    Negative battery cable

    Click image to see an enlarged view

    Fig. Alternator and related components

     

  2.  

 
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