GENERATOR & REGULATOR
1998 Mitsubishi Montero
1998 STARTING & CHARGING SYSTEMS
Mitsubishi - Generators & Regulators
Diamante, Eclipse, Galant, Mirage, Montero, Montero Sport,
3000GT
DESCRIPTION & OPERATION
NOTE: The terms generator and alternator are interchangeable.
Mitsubishi generators are conventional 3-phase, self-
rectifying type units containing 6 diodes (3 positive and 3 negative)
which are used to rectify current. All models use a case-mounted
Integrated Circuit (IC) voltage regulator.
Generator relay or resistor with diode is used to ensure
charging of battery even if charging indicator light is defective.
ADJUSTMENTS
BELT TENSION
For belt tension, see DRIVE BELT ADJUSTMENT table.
DRIVE BELT ADJUSTMENT TABLE
(1) Deflection (1) Deflection
Application New Belt In. (mm) Used Belt In. (mm)
Diamante (2) ........... .24-.28 (6.0-7.2) ..... .32-.37 (8.2-9.3)
Eclipse
2.0L Non-Turbo (3) ... .30-.41 (7.5-10.5) ... .35-.47 (9.0-12.0)
2.0L Turbo (4) ....... .30-.35 (7.5-9.0) ............ .39 (10.0)
2.4L (4) ............. .30-.35 (7.5-9.0) ............ .39 (10.0)
Galant (4) ............. .30-.35 (7.5-9.0) ............ .39 (10.0)
Mirage (3)
1.5L ................. .36-.42 (9.2-10.6) .... .26-.33 (6.6-8.3)
1.8L ................. .33-.39 (8.5-10.0) .... .28-.31 (7.0-8.0)
Montero (4) ............ .22-.29 (5.5-7.5) ..... .31-.35 (8.0-9.0)
Montero Sport
2.4L (4) ............. .22-.29 (5.5-7.5) ..... .30-.33 (7.5-8.3)
3.0L (4) ............. .22-.29 (5.5-7.5) ..... .31-.35 (8.0-9.0)
3000GT
DOHC (5) ............. .14-.16 (3.5-4.0) ..... .16-.20 (4.0-5.0)
SOHC (6) ............. .16-.20 (4.0-5.0) ..... .24-.32 (6.0-8.0)
(1) - With 22 lbs. (10 kg) pressure applied midway on belt run.
(2) - Measure between A/C compressor pulley and crankshaft pulley.
(3) - Measure between crankshaft pulley and generator pulley.
(4) - Measure between water pump pulley and generator pulley.
(5) - Measure between crankshaft pulley and idler pulley.
(6) - Measure between power steering pulley and idler pulley.
TROUBLE SHOOTING
NOTE: See TROUBLE SHOOTING article in the GENERAL INFORMATION
section.
ON-VEHICLE TESTING
GENERATOR TO BATTERY CONTINUITY TEST
NOTE: Check generator wiring harness connections and drive belt
tension and ensure battery is fully charged before
performing test.
1) Turn ignition off. Disconnect negative battery cable.
Remove output lead from generator terminal "B". See Fig. 1. Install a
100-amp or 130-amp ammeter in series with terminal "B" and
disconnected output lead. Install positive lead of ammeter to terminal
"B" and negative lead to disconnected output wire.
Fig. 1: Identifying Generator Terminals (Typical)
Courtesy of Mitsubishi Motor Sales of America
2) Install positive lead of digital voltmeter to terminal "B"
and negative lead to positive battery terminal. Install a tachometer
and reconnect negative battery cable.
3) Start and operate engine at 2500 RPM. Turn accessories on
and adjust engine speed until ammeter indicates slightly greater than
30 amps, and note voltmeter reading. If voltmeter indicates .3 volt or
less, system is okay.
4) If voltage is greater than .3 volt, check wiring between
generator terminal "B", fusible link and positive battery terminal. If
terminal is not sufficiently tight or if harness is discolored due to
overheating, repair as necessary and retest.
GENERATOR OUTPUT TEST
NOTE: A slightly discharged battery should be used, as a fully
charged battery may not allow full generator output.
1) Turn ignition off. Disconnect negative battery cable.
Disconnect generator output wire from terminal "B". Connect 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. An inductive-type
ammeter is recommended.
2) Connect positive voltmeter lead (0-20 volts) to generator
terminal "B" and negative lead to ground. Install a tachometer and
reconnect negative battery cable.
3) Ensure voltmeter indicates battery voltage. If voltage is
not present, check for open circuit in wire between generator terminal
"B" and positive battery terminal. Check grounds and fusible link.
4) Start engine and turn headlights on. Set headlights at
high beam and heater blower switch on HIGH. Increase engine speed to
2500 RPM and note generator output current on ammeter. Minimum output
should be within specification. See
GENERATOR 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 generator or
ambient temperature is excessive. Allow generator or
temperature to cool, and recheck output. Generator output is
stamped on metal plate attached to generator case.
5) If minimum output is not obtained and generator wiring is
okay, repair generator. Operate engine at idle speed after the test.
GENERATOR MINIMUM OUTPUT SPECIFICATIONS TABLE
Application Amps
Diamante ............................................. 110
Eclipse
2.0L Non-Turbo ...................................... 90
2.0L Turbo .......................................... 75
2.4L ................................................ 90
Galant ................................................ 90
Mirage ................................................ 80
Montero .............................................. 100
Montero Sport
2.4L ................................................ 60
3.0L ................................................ 85
3000GT
DOHC ............................................... 110
SOHC ................................................ 90
REGULATED VOLTAGE TEST
NOTE: Ensure battery is fully charged and proper drive belt
tension exists.
1) Turn ignition switch off. Disconnect negative battery
cable. Connect positive voltmeter lead to terminal "S" of generator.
See Fig. 1. Connect negative voltmeter lead to ground.
2) Disconnect generator output wire from terminal "B".
Install a 100-amp ammeter in series with terminal "B" and disconnected
output lead. Connect 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 on and ensure voltmeter indicates
battery voltage. If voltage is not present, check for open in wire
between generator terminal "S" and positive battery terminal. Check
for blown fusible link.
4) Start engine. Ensure all lights and accessories are off.
Operate engine at 2500 RPM and read voltmeter when generator output
current drops to 10 amps or less. Voltage regulator is okay if voltage
output is within specification. See REGULATOR VOLTAGE SPECIFICATIONS
table.
REGULATOR VOLTAGE SPECIFICATIONS TABLE
Ambient Temperature Voltage
-4 F (-20 C) ................................... 14.2-15.4
68 F (20 C) .................................... 13.9-14.9
140 F (60 C) ................................... 13.4-14.6
176 F (80 C) ................................... 13.1-14.5
GENERATOR RELAY TEST
NOTE: Information for all other models is not available from
manufacturer at time of publication.
Diamante & Mirage
Remove generator relay. On Diamante, relay is located in
relay box in engine compartment near battery. On Mirage, relay is
located in relay box in engine compartment between battery and strut
tower. On both models, connect positive lead of ohmmeter to relay
terminal No. 4. See WIRING DIAGRAMS. Connect negative lead of ohmmeter
to relay terminal No. 2. Continuity should be present. Switch ohmmeter
lead locations. Continuity should not be present. Replace generator
relay if continuity is not as specified.
BENCH TESTING
RECTIFIER ASSEMBLY
1) Using ohmmeter, check for continuity between diodes and
stator coil lead connection. See Fig. 2. Reverse leads. If continuity
is present 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. 2. Switch
ohmmeter leads. Continuity should be present in one direction only. If
continuity is not as specified, diode is defective. Replace rectifier
assembly.
Fig. 2: Testing Rectifier Assembly
Courtesy of Mitsubishi Motor Sales of America
ROTOR
1) Check continuity across rotor slip rings. Resistance
should be 3-5 ohms. Replace rotor if continuity is not present or
resistance is not within specification.
2) Check continuity between individual slip rings and rotor
shaft. If continuity is present, rotor coil or slip ring is grounded.
Replace rotor.
STATOR
Ensure continuity is not present between stator coil leads
and stator core. Check continuity between leads of stator coil. If
continuity is not present 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. See Fig. 3.
Fig. 3: Exploded View Of Mitsubishi Generator (Typical)
Courtesy of Mitsubishi Motor Sales of America
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS TABLE
Application Ft. Lbs. (N.m)
Generator Adjusting Bolt
Diamante, Mirage, Montero & Montero Sport (3.0L) ......... 16 (22)
Eclipse, Galant & Montero Sport (2.4L) .............. 9-11 (12-15)
3000GT
DOHC ................................................... 33 (44)
SOHC .............................................. 9-11 (12-15)
Generator Pivot Bolt Nut
Diamante, Mirage & 3000GT (DOHC) ......................... 33 (44)
Eclipse, Galant & Montero Sport (2.4L) ............. 15-18 (20-25)
Montero & Montero Sport (3.0L) ........................... 38 (52)
3000GT (SOHC) ...................................... 15-18 (20-25)
WIRING DIAGRAMS
Fig. 4: Charging System Wiring Diagram (Diamante)
Fig. 5: Charging System Wiring Diagram (3000GT)
Fig. 6: Charging System Wiring Diagram (Eclipse 2.0L Non-Turbo)
Fig. 7: Charging System Wiring Diagram (Eclipse 2.0L Turbo & 2.4L)
Fig. 8: Charging System Wiring Diagram (Galant)
Fig. 9: Charging System Wiring Diagram (Mirage)
Fig. 10: Charging System Wiring Diagram (Montero)
Fig. 11: Charging System Wiring Diagram (Montero Sport)
