Charging System - Lancer 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 1

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 at left.

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.

When the field current is constant, the generator output voltage rises as the engine speed increases.

Scheme 2

TROUBLESHOOTING HINTS

Generator malfunction light dose not go on when the ignition switch is turned to ON, before the engine starts.

1. Check the bulb.

Generator malfunction light dose 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) 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__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 «8. DRIVE BELT (FOR GENERATOR, POWER STEERING OIL PUMP) (CHECK CONDITION)»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/hoistjack/#general-lancer) .) YES : Go to Step 3. NO : Adjust the belt tension or replace the belt.
3. STEP 3. Q: Does the generator malfunction light come on when the ignition switch is turned on? 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) .) Check for burnt-out generator malfunction light. Check the generator. (Refer to «CHARGING SYSTEM - GENERATOR ASSEMBLY - INSPECTION»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/charging-system/#charging-system-lancer) ) 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 «CHARGING SYSTEM - GENERATOR ASSEMBLY - INSPECTION»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/charging-system/#charging-system-lancer) )
5. STEP 5. Q: Is an oscilloscope available? YES : Go to Step 6 . NO : Go to Step 7 .
6. STEP 6. Q: Dose the oscilloscope show a normal wave pattern? (Refer to «CHARGING SYSTEM - ON-VEHICLE SERVICE - WAVE PATTERN CHECK USING AN OSCILLOSCOPE»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/charging-system/#charging-system-lancer) ) YES : Go to Step 7 . NO : Check the generator. (Refer to «CHARGING SYSTEM - GENERATOR ASSEMBLY - INSPECTION»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/charging-system/#charging-system-lancer) )
7. STEP 7. Engine: 2,500 r/min Headlight: ON (high beam) Voltage between generator terminal B 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 and ground line.
8. STEP 8. Q: Is the output current normal? (Refer to «CHARGING SYSTEM - ON-VEHICLE SERVICE - OUTPUT CURRENT TEST»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/charging-system/#charging-system-lancer) ) YES : Go to Step 9 . NO : Check the generator (Refer to «CHARGING SYSTEM - GENERATOR ASSEMBLY - INSPECTION»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/charging-system/#charging-system-lancer) )
9. STEP 9. Q: Is the regulated voltage normal? (Refer to «CHARGING SYSTEM - ON-VEHICLE SERVICE - REGULATED VOLTAGE TEST»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/charging-system/#charging-system-lancer) ) YES : Go to Step 10 . NO : Check the generator (Refer to «CHARGING SYSTEM - GENERATOR ASSEMBLY - INSPECTION»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/charging-system/#charging-system-lancer) )
10. STEP 10. Q: Is the voltage drop in the generator output line normal? YES : Generator is normal. Check other systems. NO : Check the output line.

SPECIAL TOOLS

SPECIAL TOOLS SPECIFICATIONS TOOL TOOL NUMBER AND NAME SUPERSESSION APPLICATION A B C D E F G MB991958 MB991824 MB991827 MB991910 MB991911 MB991914 MB991825 MB991826 MUT-III sub assembly Vehicle communication interface (V.C.I.) MUT-III USB cable MUT-III main harness A (Vehicles with CAN communication system) MUT-III main harness B (Vehicles without CAN communication system) MUT-III main harness C (for Daimler Chrysler models only) MUT-III adapter harness MUT-III trigger harness MB991824-KIT NOTE: G: MB991826 MUT-III Trigger Harness is not necessary when pushing V.C.I. ENTER key. Checking of engine speed CAUTION: If you connect MUT-III main harness A to a vehicle without CAN communication system to use the MUT-III, a pulse signal may interfere with the simulated vehicle speed lines, thus causing the MUT-III inoperative. Therefore, use the MUT-III main harness B (MB991911) instead. MB991519 Generator harness connector MIT530 Micrd 530 charging system tester. Checking of generator ("S" terminal voltage)

Scheme 3

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Scheme 11

Required Special Tool

MB991958: Scan Tool (MUT-III Sub Assembly)

1. MB991824: V.C.I.
2. MB991827: MUT-III USB Cable
3. MB991911: MUT-III 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 «8. DRIVE BELT (FOR GENERATOR, POWER STEERING OIL PUMP) (CHECK CONDITION)»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/hoistjack/#general-lancer) .) 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. Disconnect the generator output wire from the generator "B" terminal and connect a DC test ammeter with a range of 0 - 120 A in series between the "B" terminal and the disconnected output wire. (Connect the positive lead of the ammeter to the "B" terminal, and then connect the negative lead of the ammeter to the disconnected output wire.) NOTE: A clamp-type ammeter which enables measurements to be taken without disconnecting the generator output wire is recommended. If the voltage may have dropped due to a bad connection at generator "B" terminal and the generator "B" terminal is loosened when the test ammeter is connected, the connection will be completed at this time and the possibility of finding the problem will be reduced.
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. 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. NOTE: Vehicles for Canada, the headlight, tail-light, etc. remain lit even when the lighting switch is in "OFF" position.
14. Disconnect the engine tachometer or scan tool MB991958.
15. Disconnect the negative battery cable.
16. Disconnect the ammeter and voltmeter and engine tachometer.
17. Connect the generator output wire to the generator "B" terminal.
18. Connect the negative battery cable.

Scheme 12

Required Special Tool

MB991958: Scan Tool (MUT-III Sub Assembly)

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

This test determines whether the generator outputs normal current.

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__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 «8. DRIVE BELT (FOR GENERATOR, POWER STEERING OIL PUMP) (CHECK CONDITION)»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/hoistjack/#general-lancer) .) 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 (e.g. using clips) will lead to a serious accident because of high current.
4. Disconnect the generator output wire from the generator "B" terminal and connect a DC test ammeter with a range of 0 - 120 A in series between the "B" terminal and the disconnected output wire. (Connect the positive lead of the ammeter to the "B" terminal, and then connect the negative lead of the ammeter to the disconnected output wire.) NOTE: A clamp-type ammeter which enables measurements to be taken without disconnecting the generator output wire is recommended.
5. Connect a voltmeter with a range of 0 - 20 V between the generator "B" terminal and the ground. (Connect the positive lead of the voltmeter to the "B" terminal, and then connect the negative lead of the voltmeter to the 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.
10. After turning the light switch on and 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 high revolution 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 Generator Specifications. 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, cool the generator 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, voltmeter, and engine tachometer.
18. Connect the generator output wire to the generator "B" terminal.
19. Connect the negative battery cable. Run the engine for 10 minutes at an idle after reconnecting negative battery cable.

Scheme 13

Required Special Tools

1. MB991958: Scan Tool (MUT-III Sub Assembly) MB991824: V.C.I. MB991827: MUT-III USB Cable MB991911: MUT-III 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__battery-check) .) Generator drive belt tension (Refer to «8. DRIVE BELT (FOR GENERATOR, POWER STEERING OIL PUMP) (CHECK CONDITION)»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/hoistjack/#general-lancer) .) Fusible link No 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 the 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. Disconnect the generator output wire from the generator "B" terminal.
6. Connect a DC test ammeter with a range of 0 - 120 A in series between the "B" terminal and the disconnected output wire. (Connect the positive load of the ammeter to the "B" terminal, and then connect the negative lead of the ammeter to the disconnected output wire.)
7. Reconnect the negative battery cable.
8. Connect an engine tachometer or scan tool MB991958.
9. 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.
10. Check to be sure that all lights and accessories are off.
11. Start the engine.
12. Increase the engine speed to 2,500 r/min.
13. Read the value displayed on the voltmeter when the current output by the generator becomes 10 A or less.
14. If the voltage reading is within 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).
15. After the test, lower the engine speed to the idle speed.
16. Turn the ignition switch to the "LOCK" (OFF) position.
17. Disconnect the negative battery cable.
18. Disconnect the ammeter, voltmeter and engine tachometer.
19. Connect the generator output wire to the generator "B" terminal.
20. Connect the negative battery cable.

VOLTAGE REGULATION TABLE

VOLTAGE REGULATION CHART

MEASUREMENT METHOD

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

Scheme 14

STANDARD WAVEFORM

STANDARD WAVEFORM

Scheme 15

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.

Scheme 16

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.

Scheme 17

Scheme 18

Scheme 19

Scheme 20

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 stator coil.

REMOVAL AND INSTALLATION < 2.0L ENGINE >

Scheme 21

<< A >> ENGINE MOUNTING INSULATOR < VEHICLES WITH ABS > REMOVAL

1. Remove all the power steering hose clamp mounting bolts.
2. Jack up and support the engine assembly, and remove the engine mounting insulator.
3. Tilt the engine to remove the generator.

GENERATOR REMOVAL

Remove the generator from above the vehicle.

Scheme 22

<< A >> GENERATOR REMOVAL

Remove the generator from above the vehicle.

Scheme 23

<< A >> FRONT BRACKET ASSEMBLY REMOVAL

Insert a flat-tipped screwdriver between the front bracket assembly and the stator core, and pry it downward to separate the stator and front bracket assembly.

Scheme 24

<< B >> GENERATOR PULLEY REMOVAL

Set the pulley upward, clamp the rotor in a vise, and remove the pulley.

Scheme 25

<< C >> STATOR REMOVAL

1. Use a soldering iron (180 to 250 W) to unsolder the stator. This work should be completed within approximately four seconds, to prevent heat from transferring to the diode.
2. When removing the rectifier from the regulator assembly, unsolder the points soldered on the rectifier.

Scheme 26

>>A<< REGULATOR ASSEMBLY INSTALLATION

After installing the regulator assembly, insert a wire through the hole provided on the rear bracket while pressing down on the brush, and secure the brush.

Note. By inserting a wire, the brush will be secured in place, and the installation of the rotor will be easier.

Scheme 27

Scheme 28

>>B<< ROTOR ASSEMBLY INSTALLATION

After installing the rotor, remove the wire used to secure the brush.

Scheme 29

Scheme 30

Scheme 31

1. Check for continuity between the slip rings of the field coil. If the resistance value is not within the standard value, replace the rotor. Standard value: approximately 2 - 5 ohms
2. Check for continuity between the slip ring and the core. If there is continuity, replace the rotor.

Scheme 32

Scheme 33

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

Scheme 34

Scheme 35

Scheme 36

1. Check for continuity between the positive rectifier and the stator coil lead connection terminal with a tester. If there is continuity between the terminals, the diode is shorted, so replace the rectifier.
2. Check for continuity between the negative rectifier and the stator coil lead connection terminal with a tester. If there is continuity between the terminals, the diode is grounded, so replace the rectifier.
3. Check for continuity of the three diodes by connecting an ohmmeter to both ends of each diode. If there is continuity between the directions, or if there is no continuity, the diode is damaged, so replace the rectifier.

Scheme 37

Scheme 38

1. Replace the brush if the brush protrusion length shown in the illustration is below the minimum limit value. Minimum limit: 2 mm (0.08 inch)
2. The brush can be removed by unsoldering the brush lead wire.
3. When installing a new brush, push the brush in to the brush holder, and solder the lead wire.

See also:
• BATTERY CHECK
• 8. DRIVE BELT (FOR GENERATOR, POWER STEERING OIL PUMP) (CHECK CONDITION)
• INSPECTION
• CHARGING SYSTEM - GENERATOR ASSEMBLY - INSPECTION