Charging System - Lancer Evolution Mitsubishi Lancer Evolution IX

GENERAL DESCRIPTION

The charging system charges the battery with the generator output to keep the battery charged at a constant level during varying electrical load.

Scheme 39

Rotation of the excited field coil generates AC voltage in the stator.

This alternating current is rectified through diodes to DC voltage having a waveform shown in the illustration above.

The average output voltage fluctuates slightly with the generator load condition.

When the ignition switch is turned on, current flows in the field coil and initial excitation of the field coil occurs.

When the stator coil begins to generate power after the engine is started, the field coil is excited by the output current of the stator coil.

The generator output voltage rises as the field current increases and it falls as the field current decreases. When the battery positive voltage (generator S terminal voltage) reaches a regulated voltage of approximately 14.4 V, the field current is cut off. When the battery positive voltage drops below the regulated voltage, the voltage regulator regulates the output voltage to a constant level by controlling the field current.

In addition, when the field current is constant, the generator output voltage rises as the engine speed increases.

Scheme 40

SPECIAL TOOL

SPECIAL TOOL TOOL TOOL NUMBER AND NAME SUPERSESSION APPLICATION MB991958 Scantool (M.U.T.-III sub assembly) MB991824 Vehicle communication interface (V.C.I.) MB991827 M.U.T.-III USB cable MB991910 M.U.T.-III main harness A (Vehicles with CAN communication system) MB991911 M.U.T.-III main harness B (Vehicles without CAN communication system) MB991914 M.U.T.-III main harness C (for Daimler Chrysler models only) MB991825 M.U.T.-III measurement adapter MB991826 M.U.T.-III trigger harness MB991824-KIT NOTE: G: MB991826 M. U. T. -III Trigger Harness is not necessary when pushing V.C.I. ENTER key. Checking of engine idle speed CAUTION: M.U.T.-III main harness B (MB991911) should be used. M.U.T.-III main harness A and C should not be used for this vehicle. MB991519 Generator harness connector MIT530 Micrd 530 charging system tester. Checking of generator ("S" terminal voltage)

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TROUBLESHOOTING HINTS

Generator malfunction light does not come on when the ignition switch is turned to "ON" position, before the engine starts.

1. Check the bulb.

Generator malfunction light does not switch off after the engine starts.

1. Check the IC voltage regulator inside the generator.

Discharged or overcharged battery.

1. Check the IC voltage regulator inside the generator.

The generator malfunction light illuminates dimly.

1. Check the diode (inside the combination meter or generator) for a short-circuit.

TROUBLESHOOTING GUIDE

The charging system troubleshooting guide is shown in the following steps.

1. STEP 1. Q: Is the battery in good condition? (Refer to «BATTERY CHECK»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/antenna-systems/#chassis-electrical-lancer-evolution__battery-check) .) YES: Go to Step 2. NO: Charge or replace the battery.
2. STEP 2. Q: Is the generator drive belt in good condition? (Refer to «DRIVE BELT (FOR GENERATOR, WATER PUMP AND POWER STEERING OIL PUMP) (CHECK CONDITION)»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/hoistjack/#general-lancer-evolution) .) YES: Go to Step 3. NO: Adjust the belt tension or replace the belt.
3. STEP 3. Does the generator malfunction light turn on brightly when the ignition switch is turned to the "ON" position? YES: Go to Step 4. NO: Check the ignition switch. (Refer to «INSPECTION»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/antenna-systems/#chassis-electrical-lancer-evolution__inspection) .) Check for burnt-out generator malfunction light bulb. Check the generator. (Refer to «INSPECTION»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/charging-system/#charging-system-lancer-evolution) .) Check the generator malfunction light-related circuits.
4. STEP 4. Q: Does the generator malfunction light go out after starting the engine? YES: Go to Step 5. NO: Check the generator (Refer to «INSPECTION»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/charging-system/#charging-system-lancer-evolution) .)
5. STEP 5. Q: Is an oscilloscope available? YES: Go to Step 6. NO: Go to Step 7 .
6. STEP 6. Q: Does the oscilloscope show a normal wave pattern? (Refer to «WAVE PATTERN CHECK USING AN OSCILLOSCOPE»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/charging-system/#charging-system-lancer-evolution) .) YES: Go to Step 7. NO: Check the generator. (Refer to «INSPECTION»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/charging-system/#charging-system-lancer-evolution) .)
7. STEP 7. Engine: 2,500 r/min Headlight: ON (high beam) Voltage between generator "B" terminal and the positive battery terminal OK: 0.5 V or less Voltage between the negative battery terminal and generator body OK: 0.5 V or less Q: Are the generator output line and ground line in good condition? YES: Go to Step 8. NO: Check the generator output line. Check the generator ground line.
8. STEP 8. Q: Is the output current normal? (Refer to «OUTPUT CURRENT TEST»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/charging-system/#charging-system-lancer-evolution) .) YES: Go to Step 9. NO: Check the generator (Refer to «INSPECTION»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/charging-system/#charging-system-lancer-evolution) .)
9. STEP 9. Q: Is the regulated voltage normal? (Refer to Refer to «REGULATED VOLTAGE TEST»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/charging-system/#charging-system-lancer-evolution) .) YES: Go to Step 10. NO: Check the generator (Refer to «INSPECTION»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/charging-system/#charging-system-lancer-evolution) .)
10. STEP 10. Q: Are the voltage drops in the generator output line normal? (Refer to «GENERATOR OUTPUT LINE VOLTAGE DROP TEST»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/charging-system/#charging-system-lancer-evolution) .) YES: Generator is normal. Check other systems. NO: Check the output line.

Scheme 49

Required Special Tool

MB991958: Scan Tool (M.U.T.-III Sub Assembly)

1. MB991824: V.C.I.
2. MB991827: USB Cable
3. MB991911: Main Harness B

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

1. Always be sure to check the following before the test. Generator installation Generator drive belt tension (Refer to «DRIVE BELT (FOR GENERATOR, WATER PUMP AND POWER STEERING OIL PUMP) (CHECK CONDITION)»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/hoistjack/#general-lancer-evolution) .) Fusible link Abnormal noise from the generator while the engine is running.
2. Turn the ignition switch to the "LOCK" (OFF) position.
3. Disconnect the negative battery cable.
4. Connect a clamp-type DC test ammeter with a range of 0 - 100 A to the generator "B" terminal output wire. NOTE: Disconnecting the generator output wire and connecting the ammeter may not determine the problem if there is insufficient connection between terminal "B" and the output wire.
5. Connect a digital-type voltmeter between the generator "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.)
6. Reconnect the negative battery cable.
7. Connect an engine tachometer or scan tool MB991958.
8. Leave the hood open.
9. Start the engine.
10. With the engine running at 2,500 r/min, turn the headlights and other lights on and off to adjust the generator 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 generator and battery is OK. Limit value: maximum 0.3 V NOTE: When the generator 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.
11. If the value displayed on the voltmeter is above the limit value, there is probably a malfunction in the generator output wire. Check the wiring between the generator "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.
14. Disconnect the engine tachometer or scan tool MB991958.
15. Disconnect the negative battery cable.
16. Disconnect the ammeter and voltmeter.
17. Connect the negative battery cable.
18. Run the engine for 10 minutes at an idle.

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Required Special Tool

MB991958: Scan Tool (M.U.T.-III Sub Assembly)

1. MB991824: V.C.I.
2. MB991827: USB Cable
3. MB991911: Main Harness B

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

1. Before the test, always be sure to check the following. Generator installation Battery (Refer to «BATTERY CHECK»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/antenna-systems/#chassis-electrical-lancer-evolution__battery-check) .) 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. Generator drive belt tension (Refer to «DRIVE BELT (FOR GENERATOR, WATER PUMP AND POWER STEERING OIL PUMP) (CHECK CONDITION)»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/hoistjack/#general-lancer-evolution) .) Fusible link Abnormal noise from the generator while the engine is running.
2. Turn the ignition switch to the "LOCK" (OFF) position.
3. Disconnect the negative battery cable. WARNING: Never use clips to connect the line. Loose connections (for example, using clips) will lead to a serious accident because of high current.
4. Connect a clamp-type DC test ammeter with a range of 0 - 100 A to the generator "B" terminal output wire.
5. Connect a voltmeter with a range of 0 -20 V between the generator "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.)
6. Connect the negative battery cable.
7. Connect an engine tachometer or scan tool MB991958.
8. Leave the hood open.
9. 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 generator "B" terminal and the battery positive terminal or malfunctioning voltmeter.
10. 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.
11. 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: For the nominal current output, refer to the . NOTE: The current output value will depend on the electrical load and the temperature of the generator body. NOTE: If the electrical load is small while testing, the specified level of current may not be output even though the generator 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 generator body or the ambient temperature is too high. In such cases, allow the generator to cool and then test again.
12. The reading on the ammeter should be above the limit value. If the reading is below the limit value and the generator output wire is normal, remove the generator from the engine and check the generator.
13. Run the engine at idle speed after the test.
14. Turn the ignition switch to the "LOCK" (OFF) position.
15. Disconnect the engine tachometer or scan tool MB991958.
16. Disconnect the negative battery cable.
17. Disconnect the ammeter and voltmeter.
18. Connect the negative battery cable.
19. Run the engine for 10 minutes at idle.

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Required Special Tools

1. MB991958: Scan Tool (M.U.T.-III Sub Assembly) MB991824: V.C.I. MB991827: USB Cable MB991911: Main Harness B
2. MB991519: Generator Harness Connector

This test determines whether the voltage regulator is correctly controlling the generator output voltage.

1. Always be sure to check the following before the test: Generator installation Check to be sure that the battery installed in the vehicle is fully charged. (Refer to «BATTERY CHECK»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/antenna-systems/#chassis-electrical-lancer-evolution__battery-check) .) Generator drive belt tension (Refer to «DRIVE BELT (FOR GENERATOR, WATER PUMP AND POWER STEERING OIL PUMP) (CHECK CONDITION)»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/hoistjack/#general-lancer-evolution) .) Fusible link Abnormal noise from the generator while the engine is running.
2. Turn the ignition switch to the "LOCK" (OFF) position.
3. Disconnect the negative battery cable.
4. Use the special tool (Generator harness connector: MB991519) to connect a digital-type voltmeter between the generator "S" terminal and ground. (Connect the positive lead of the voltmeter to the "S" terminal, and then connect the negative lead of the voltmeter to a secure ground or to the negative battery terminal.)
5. Connect a clamp-type DC test ammeter with a range of 0 -100 A to the generator "B" terminal output wire.
6. Reconnect the negative battery cable.
7. Connect an engine tachometer or scan tool MB991958.
8. Turn the ignition switch to the "ON" position and check 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 generator "S" terminal and the battery positive terminal or malfunctioning voltmeter.
9. Check to be sure that all lights and accessories are off.
10. Start the engine.
11. Increase the engine speed to 2,500 r/min.
12. Read the value displayed on the voltmeter when the current output by the generator becomes 10 A or less.
13. If the voltage reading conforms to the value in the voltage regulation table, then the voltage regulator is operating normally. If the voltage is outside the standard value, there is a malfunction of the voltage regulator or the generator (Refer to the following table «VOLTAGE REGULATION TABLE»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/charging-system/#charging-system-lancer-evolution) ).
14. After the test, lower the engine speed to idle.
15. Turn the ignition switch to the "LOCK" (OFF) position.
16. Disconnect the engine tachometer or scan tool MB991958.
17. Disconnect the negative battery cable.
18. Disconnect the ammeter and voltmeter.
19. Connect the negative battery cable.
20. Run the engine for 10 minutes at idle.

VOLTAGE REGULATION TABLE

VOLTAGE REGULATION TABLE

MEASUREMENT METHOD

Connect the oscilloscope special patterns pick-up to the generator "B" terminal.

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STANDARD WAVEFORM

WAVEFORM FUNCTION CHART

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Note. The voltage waveform of the generator "B" terminal can undulate as shown at left. This waveform is produced when the regulator operates according to fluctuations in the generator load (current), and is normal for the generator.

If the ripple height is abnormally high (approximately 2 V or more during idling), the wires between the generator "B" terminal and the battery have broken due to fuse blowing, etc. The generator is usually operating properly . Voltage Waveform Graph

Scheme 54

ABNORMAL WAVEFORMS EXAMPLES

Note. The size of the waveform patterns can differ greatly, depending on the adjustment of the variable knob on the oscilloscope.

Note. Identification of abnormal waveforms is easier when there is a large output current (regulator is not operating). (Waveforms can be observed when the headlights are illuminated.)

Note. Check the conditions of the generator malfunction light (illuminated/not illuminated) also, and carry out a total check.

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1. Example 1 PROBABLE CAUSE: Open circuit in diode
2. Example 2 PROBABLE CAUSE: Short-circuit in diode
3. Example 3 PROBABLE CAUSE: Open circuit in stator coil
4. Example 4 PROBABLE CAUSE: Short-circuit in stator coil

REMOVAL AND INSTALLATION

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<< A >> FUEL INJECTOR, FUEL RAIL, FUEL RETURN PIPE AND FUEL PRESSURE REGULATOR ASSEMBLY REMOVAL

After loosening the fuel rail mounting bolts, move the fuel injector, fuel rail, fuel return pipe and the fuel pressure regulator as an assembly aside in order to make room for the generator removal.

<< B >> DRIVE BELT REMOVAL

The following operations will be needed due to the serpentine drive system with the drive belt auto-tensioner.

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1. Securely insert the spindle handle or ratchet handle with a 12.7 mm (1/2-inch) insertion angle into the jig hole of the auto-tensioner, and turn the auto-tensioner counterclockwise until it hits the stopper. The following operations will be needed due to the serpentine drive system with the drive belt auto-tensioner.
2. Align hole A with hole B, insert an L-shaped hexagon wrench, etc. to fix and then remove the drive belt.

<< C >> GENERATOR REMOVAL

Raise the engine with a floor jack and remove the generator upward from the engine room.

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<< A >> FRONT BRACKET ASSEMBLY REMOVAL

Insert the blades of screwdrivers between the front bracket assembly and stator core, and pry and separate them with the screwdrivers.

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<< B >> ALTERNATOR PULLEY REMOVAL

Clamp the rotor in a vise with the pulley facing up to remove the pulley.

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<< C >> STATOR / REGULATOR ASSEMBLY REMOVAL

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1. Unsolder the stator leads from the main diode of the rectifier assembly when the stator is removed.
2. When removing the rectifier assembly from the regulator assembly, undo the soldered points on the rectifier assembly.

>> A << REGULATOR ASSEMBLY INSTALLATION

After installing the regulator assembly, insert a piece of wire through the hole in the rear bracket while pressing the brush to keep the brush against movement.

Note. Holding the brush with the wire assists installation of the rotor.

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>> B << ROTOR INSTALLATION

Remove the brush holding wire after the rotor has been installed.

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1. Measure the resistance between the two slip rings of the rotor coil to check the continuity between them. Replace the rotor if the resistance is not within the standard value range. Standard value: 3 - 5 +/
2. Check the continuity between the slip rings and core. If continuity is present, replace the rotor.

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1. Check the continuity between coil leads. If there is no continuity, replace the stator.
2. Check the continuity between coil and core. If there is no continuity, replace the stator.

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1. Check the condition of the (+) heat sink by checking continuity between the (+) heat sink and each of the stator coil lead connecting terminals. If continuity is present for both terminals, the diode is shorted. Replace the rectifier assembly.
2. Check the condition of the (-) heat sink by checking continuity between the (-) heat sink and each of the stator coil lead connecting terminals. If continuity is present in both directions, the diode is shorted. Replace the rectifier assembly.
3. Check the condition of the diode trio by testing continuity of each of the three diodes using a circuit tester connected to both sides of the diode. If the same reading results for both polarities, the diode is defective. Replace the rectifier assembly if any of the diodes is defective.

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1. Measure the length of the protrusion of the brush. Replace the brush if the protrusion length is shorter than the limit. Limit: 2 mm minimum
2. Unsolder the lead of the brush. The brush will come out, ready for removal.
3. Install a new brush by pushing it into the holder as shown in the drawing and soldering the lead.

See also:
• BATTERY CHECK
• DRIVE BELT (FOR GENERATOR, WATER PUMP AND POWER STEERING OIL PUMP) (CHECK CONDITION)
• INSPECTION
• INSPECTION