Mitsubishi Montero (1998+). Manual - part 196

         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