Mitsubishi Outlander 2003-06

Alternator

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Diagnosis & Testing



Alternator Output Test

NOTE
This procedure requires the following special tools, or their equivalents:



MB991958: Scan Tool (M.U.T.-III Sub Assembly)
 
MB991824: V.C.I.
 
MB991827: M.U.T.-III USB Cable
 
MB991910: M.U.T.-III Main Harness A
 

This test determines whether the alternator outputs normal current. For best results, use a charging system tester. If not available, follow the steps below.


CAUTION
Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING.

  1. Before the test, always be sure to check the following:
    1. Alternator installation
    2.  
    3. Battery
      NOTE
      The battery to be used should be slightly discharged. The load in a fully-charged battery will be insufficient and the test may not be able to be carried out correctly.

    4.  
    5. Alternator drive belt tension. For more information, refer to the Engine Mechanical Section.
    6.  
    7. Fusible link
    8.  
    9. Abnormal noise from the alternator while the engine is running.
    10.  

  2.  
  3. Turn the ignition switch to the "LOCK" (OFF) position.
  4.  
  5. Disconnect the negative battery cable.
    CAUTION
    Never use clips to connect the line. Loose connections (for example, using clips) will lead to a serious accident because of high current.

  6.  
  7. Connect a clamp-type DC test ammeter with a range of 0 - 150 A to the alternator "B" terminal output wire.
  8.  
  9. Connect a voltmeter with a range of 0 - 20 V between the alternator "B" terminal and ground. (Connect the positive lead of the voltmeter to the "B" terminal, and then connect the negative lead of the voltmeter to ground.)
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Connect an engine tachometer or scan tool MB991958.

    Click image to see an enlarged view

    Fig. Output current test connections

  14.  
  15. Leave the hood open.
  16.  
  17. Check to be sure that the reading on the voltmeter is equal to the battery positive voltage.
    NOTE
    If the voltage is 0 V, the cause is probably an open circuit in the wire or fusible link between the alternator "B" terminal and the battery positive terminal or malfunctioning voltmeter.

  18.  
  19. After turning on the headlights, start the engine.
    NOTE
    Because the current from the battery will soon drop after the engine is started, step 11 should be carried out as quickly as possible in order to obtain the maximum current output value.

  20.  
  21. Immediately after setting the headlights to high beam and turning the heater blower switch to the highest position, increase the engine speed to 2,500 r/min and read the maximum current output value displayed on the ammeter. Limit value: 70 % of nominal current output
    NOTE
    The current output value will depend on the electrical load and the temperature of the alternator body.


    NOTE
    If the electrical load is small while testing, the specified level of current may not be output even though the alternator is normal. In such cases, increase the electrical load by leaving the headlights turned on for some time to discharge the battery or by using the lighting system in another vehicle, and then test again.


    NOTE
    The specified level of current also may not be output if the temperature of the alternator body or the ambient temperature is too high. In such cases, cool the alternator and then test again.

  22.  
  23. The reading on the ammeter should be above the limit value. If the reading is below the limit value and the alternator output wire is normal, remove the alternator from the engine and check the alternator.
  24.  
  25. Run the engine at idle speed after the test.
  26.  
  27. Turn the ignition switch to the "LOCK" (OFF) position.
  28.  
  29. Disconnect the engine tachometer or scan tool MB991958.
  30.  
  31. Disconnect the negative battery cable.
  32.  
  33. Disconnect the ammeter and voltmeter .
  34.  
  35. Connect the negative battery cable.
  36.  
  37. Run the engine for 10 minutes at an idle.
  38.  

Output Line Voltage Drop Test

NOTE
This procedure requires the following special tools, or their equivalents:



MB991958: Scan Tool (M.U.T.-III Sub Assembly)
 
MB991824: V.C.I.
 
MB991827: M.U.T.-III USB Cable
 
MB991910: M.U.T.-III Main Harness A
 

This test determines whether the wiring from the alternator "B" terminal to the positive battery terminal (including the fusible link) is in good condition or not.


CAUTION
Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING.

  1. Always be sure to check the following before the test:
    1. Alternator installation
    2.  
    3. Alternator drive belt tension. For more information, refer to the Engine Mechanical Section.
    4.  
    5. Fusible link
    6.  
    7. Abnormal noise from the alternator while the engine is running.
    8.  

  2.  
  3. Turn the ignition switch to the "LOCK" (OFF) position.
  4.  
  5. Disconnect the negative battery cable.

    Click image to see an enlarged view

    Fig. Output line voltage drop test connections

  6.  
  7. Connect a clamp-type DC test ammeter with a range of 0 - 150 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.

  8.  
  9. Connect a digital-type voltmeter between the alternator "B" terminal and the positive battery terminal. (Connect the positive lead of the voltmeter to the "B" terminal, and then connect the negative lead of the voltmeter to the positive battery cable.)
  10.  
  11. Reconnect the negative battery cable.
  12.  
  13. Connect an engine tachometer or scan tool MB991958.
  14.  
  15. Leave the hood open.
  16.  
  17. Start the engine.
  18.  
  19. With the engine running at 2,500 r/min, turn the headlights and other lights on and off to adjust the alternator load so that the value displayed on the ammeter is slightly above 30 A. Read the voltmeter. Voltage reading at or below limit value means voltage drop between alternator and battery is OK. Limit value: maximum 0.3 V
    NOTE
    When the alternator output is high and the value displayed on the ammeter does not decrease to 30 A, set the value to 40 A. Read the value displayed on the voltmeter at this time. In this case the limit value becomes maximum 0.4 V. Adjust the engine speed by gradually decreasing it until the value displayed on the ammeter is 30 A. Take a reading of the value displayed on the voltmeter at this time.

  20.  
  21. If the value displayed on the voltmeter is above the limit value, there is probably a malfunction in the alternator output wire. Check the wiring between the alternator "B" terminal and the positive battery terminal (including fusible link).If a terminal is not sufficiently tight or if the harness has become discolored due to overheating, repair and then test again.12.After the test, run the engine at idle. 13.Turn off all lights and turn the ignition switch to the "LOCK" (OFF) position.
    NOTE
    For Canadian models, the headlight, taillight, etc. remain lit even when the lighting switch is in "OFF" position.

  22.  
  23. Disconnect the engine tachometer or scan tool MB991958.
  24.  
  25. Disconnect the negative battery cable.
  26.  
  27. Disconnect the ammeter and voltmeter.
  28.  
  29. Connect the negative battery cable.
  30.  
  31. Run the engine for 10 minutes at an idle.
  32.  

Removal & Installation



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

    Negative battery cable
     
    Engine undercover
     
    Drive belt
     
    A/C compressor connector and connector clamp
     
    Alternator connector and terminal
     
    Alternator connector bracket
     
    Harness bracket
     
    Alternator, lifting it up out of the vehicle
     

  4.  
  5. If necessary, remove the lower timing belt cover and alternator mounting bracket.
  6.  


    Click image to see an enlarged view

    Fig. Exploded view of the alternator and related components


To install:

  1. If removed, install the alternator mounting bracket and lower timing belt cover.
  2.  
  3. Install or connect the following:

    Alternator, lifting it up out of the vehicle
     
    Harness bracket
     
    Alternator connector bracket
     
    Alternator terminal and connector
     
    A/C compressor connector clamp and connector
     
    Drive belt
     
    Engine undercover
     
    Negative battery cable
     

  4.  

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

    Negative battery cable
     
    Engine undercover
     
    Drive belt
     
    A/C compressor connector and connector clamp
     
    Alternator connector and terminal
     
    Alternator connector bracket
     
    Harness bracket
     
    Alternator, lifting it up out of the vehicle

    Click image to see an enlarged view

    Fig. Alternator and related components

     

  4.  
  5. If necessary, remove the lower timing belt cover and alternator mounting bracket.
  6.  

To install:

  1. If removed, install the alternator mounting bracket and lower timing belt cover.
  2.  
  3. Install or connect the following:

    Alternator, lifting it up out of the vehicle
     
    Harness bracket
     
    Alternator connector bracket
     
    Alternator terminal and connector
     
    A/C compressor connector clamp and connector
     
    Drive belt
     
    Engine undercover
     
    Negative battery cable
     

  4.  

 
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