Charging System - Except Lancer Evolution Mitsubishi Lancer Evolution X

GENERAL INFORMATION

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 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 2

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

SERVICE SPECIFICATIONS

SERVICE SPECIFICATIONS

TROUBLESHOOTING HINTS

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

1. Check the generator malfunction light.

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.

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/x-2007-2016/remont/body-electrical/#battery-except-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 BELTS (FOR GENERATOR AND POWER STEERING OIL PUMP) (CHECK CONDITION)»(/mitsubishi/lancer-evolution/x-2007-2016/remont/hoistjack/#general-information-except-lancer-evolution) < 2.0 L ENGINE Non-turbo, 2.4 L ENGINE >, «DRIVE BELT (FOR THE GENERATOR AND POWER STEERING OIL PUMP)»(/mitsubishi/lancer-evolution/x-2007-2016/remont/hoistjack/#general-information-except-lancer-evolution) < 2.0 L ENGINE Turbo >]. 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/x-2007-2016/remont/ignition-switchsteering-lock/#ignition-switch-except-lancer-evolution) ). Check the generator malfunction light and its related circuits. Check the generator. Refer to «INSPECTION»(/mitsubishi/lancer-evolution/x-2007-2016/remont/charging-system/#charging-system-except-lancer-evolution) .
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/x-2007-2016/remont/charging-system/#charging-system-except-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/x-2007-2016/remont/charging-system/#charging-system-except-lancer-evolution) .) YES: Go to Step 7. NO: Check the generator. Refer to «INSPECTION»(/mitsubishi/lancer-evolution/x-2007-2016/remont/charging-system/#charging-system-except-lancer-evolution) .
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 «OUTPUT CURRENT TEST»(/mitsubishi/lancer-evolution/x-2007-2016/remont/charging-system/#charging-system-except-lancer-evolution) .) YES: Go to Step 9. NO: Check the generator. Refer to «INSPECTION»(/mitsubishi/lancer-evolution/x-2007-2016/remont/charging-system/#charging-system-except-lancer-evolution) .
9. STEP 9. Q: Is the regulated voltage normal? (Refer to «REGULATED VOLTAGE TEST»(/mitsubishi/lancer-evolution/x-2007-2016/remont/charging-system/#charging-system-except-lancer-evolution) .) YES: Go to Step 10. NO: Check the generator. Refer to «INSPECTION»(/mitsubishi/lancer-evolution/x-2007-2016/remont/charging-system/#charging-system-except-lancer-evolution) .
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 TOOL TOOL NUMBER AND NAME SUPERSESSION APPLICATION MB991958 Scan tool (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 speed CAUTION: For vehicles with CAN communication, use M.U.T.-III main harness A to send simulated vehicle speed. If you connect M.U.T.-III main harness B instead, the CAN communication does not function correctly. MB991519 Generator harness connector MIT530 Micrd 530 charging system tester. Checking of generator ("S" terminal voltage) MB992226 Serration socket - Removal and installation of alternator's one way clutch

Scheme 3

Scheme 4

Scheme 5

Required Special Tool

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

1. MB991824: V.C.I.
2. MB991827: M.U.T.-III USB Cable
3. MB991910: M.U.T.-III Main Harness A

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 BELTS (FOR GENERATOR AND POWER STEERING OIL PUMP) (CHECK CONDITION)»(/mitsubishi/lancer-evolution/x-2007-2016/remont/hoistjack/#general-information-except-lancer-evolution) < 2.0 L ENGINE Non-turbo, 2.4 L ENGINE > or «DRIVE BELT (FOR THE GENERATOR AND POWER STEERING OIL PUMP)»(/mitsubishi/lancer-evolution/x-2007-2016/remont/hoistjack/#general-information-except-lancer-evolution) < 2.0 L ENGINE Turbo >]. 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. Set a clamp-type DC test ammeter to the generator "B" terminal output wire. NOTE: Disconnecting the generator output wire and connecting the ammeter may not thoroughly diagnosis an output current drop problem because of an 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 headlamps and other lamps on and off to adjust the generator load so that the value displayed on the ammeter is slightly above 30 A. Adjust the engine speed by gradually decreasing it until the value displayed on the ammeter is 30 A. Take a reading of the valve displayed on the voltmeter at this time. Limit: maximum 0.3 V NOTE: When the generator output is high and the value displayed on the ammeter does not decrease until 30 A, set the value to 40 A. Read the value displayed on the voltmeter at this time. When the value range is 40 A, the limit is maximum 0.4 V.
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, taillight, 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. Remove the ammeter and voltmeter.
17. Connect the negative battery cable.

Scheme 6

Required Special Tool

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

1. MB991824: V.C.I.
2. MB991827: M.U.T.-III USB Cable
3. MB991910: M.U.T.-III Main Harness A

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/x-2007-2016/remont/body-electrical/#battery-except-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 BELTS (FOR GENERATOR AND POWER STEERING OIL PUMP) (CHECK CONDITION)»(/mitsubishi/lancer-evolution/x-2007-2016/remont/hoistjack/#general-information-except-lancer-evolution) < 2.0 L ENGINE Non-turbo, 2.4 L ENGINE > or «DRIVE BELT (FOR THE GENERATOR AND POWER STEERING OIL PUMP)»(/mitsubishi/lancer-evolution/x-2007-2016/remont/hoistjack/#general-information-except-lancer-evolution) < 2.0 L ENGINE Turbo >]. 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. Set a clamp-type DC test ammeter to the generator "B" terminal output wire. NOTE: Disconnecting the generator output wire and connecting the ammeter may not thoroughly diagnosis an output current drop problem because of an insufficient connection between terminal "B" and the 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, turning on the air conditioner switch 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 «GENERAL SPECIFICATIONS»(/mitsubishi/lancer-evolution/x-2007-2016/remont/charging-system/#charging-system-except-lancer-evolution__general-specifications) and «SERVICE SPECIFICATIONS»(/mitsubishi/lancer-evolution/x-2007-2016/remont/charging-system/#charging-system-except-lancer-evolution__service-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 and voltmeter.
18. Connect the negative battery cable.

Scheme 7

Required Special Tools

1. 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
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/x-2007-2016/remont/body-electrical/#battery-except-lancer-evolution__battery-check) .) Generator drive belt tension [Refer to «DRIVE BELTS (FOR GENERATOR AND POWER STEERING OIL PUMP) (CHECK CONDITION)»(/mitsubishi/lancer-evolution/x-2007-2016/remont/hoistjack/#general-information-except-lancer-evolution) < 2.0 L ENGINE Non-turbo, 2.4 L ENGINE > or «DRIVE BELT (FOR THE GENERATOR AND POWER STEERING OIL PUMP)»(/mitsubishi/lancer-evolution/x-2007-2016/remont/hoistjack/#general-information-except-lancer-evolution) < 2.0 L ENGINE Turbo >]. 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. Set a clamp-type DC test ammeter 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. NOTE: Do not drive the vehicle after the engine starts.
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 15 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 «VOLTAGE REGULATION REFERENCE TABLE»(/mitsubishi/lancer-evolution/x-2007-2016/remont/charging-system/#charging-system-except-lancer-evolution) ). NOTE: When the voltage is approximately 12.8 V, the G-terminal is supposed to have a short circuit to the ground. Check the circuits relating to the G-terminal on the generator. [Refer to «SYMPTOM CHART»(/mitsubishi/lancer-evolution/x-2007-2016/remont/testing-diagnostics/#multiport-fuel-injection-mfi-20l-non-turbo-except-lancer-evolution) < 2.0L ENGINE Non-turbo >] [Refer to «SYMPTOM CHART»(/mitsubishi/lancer-evolution/x-2007-2016/remont/testing-diagnostics/#multiport-fuel-injection-mfi-20l-turbo-except-lancer-evolution) < 2.0L ENGINE Turbo >] [Refer to «SYMPTOM CHART»(/mitsubishi/lancer-evolution/x-2007-2016/remont/testing-diagnostics/#multiport-fuel-injection-mfi-24l-except-lancer-evolution) < 2.4L ENGINE >]
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. Remove the special tool (Generator harness connector: MB991519), and return the connector to the original condition.
20. Connect the negative battery cable.

VOLTAGE REGULATION TABLE

VOLTAGE REGULATION REFERENCE TABLE

MEASUREMENT METHOD

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

Scheme 8

STANDARD WAVEFORM

STANDARD WAVEFORM TABLE

Scheme 9

Scheme 10

Note. The voltage waveform of the generator "B" terminal can undulate as shown in illustration. 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.

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 11

Scheme 12

Scheme 13

Scheme 14

1. Example 1 PROBABLE CAUSE: Open circuit or short circuit in diode
2. Example 2 PROBABLE CAUSE: Open circuit in stator coil (In stator coil)
3. Example 3 PROBABLE CAUSE: Open circuit in stator coil (Open circuit between stator coil and diode)
4. Example 4 PROBABLE CAUSE: Short circuit in stator coil

Scheme 15

<< A >> A/C COMPRESSOR AND CLUTCH ASSEMBLY REMOVAL

1. With the hose installed, remove the A/C compressor and clutch assembly from the bracket.
2. Tie the removed A/C compressor and clutch assembly with a string at a position where it will not interfere with the removal and installation of the generator assembly.

<< B >> GENERATOR ASSEMBLY REMOVAL

Remove the generator assembly to the downside.

Scheme 16

1. Install the grounding cable within the area marked with A in the illustration.
2. Tighten the generator assembly mounting bolt to the specified torque. Tightening torque: 44 ± 10 N.m (33 ± 7 ft-lb)

>> B << A/C COMPRESSOR AND CLUTCH ASSEMBLY INSTALLATION

Tighten A/C compressor and clutch assembly mounting bolts to the specified torque in the order of number shown in the illustration.

Tightening torque: 23 ± 6 N.m (17 ± 4 ft-lb)

Scheme 17

Scheme 18

1. With the hose installed, remove the A/C compressor and clutch assembly from the bracket.
2. Tie the removed A/C compressor and clutch assembly with a string at a position where it will not interfere with the removal and installation of the generator assembly.

Remove the generator assembly upward.

>> A << A/C COMPRESSOR AND CLUTCH ASSEMBLY INSTALLATION

Tighten A/C compressor and clutch assembly mounting bolts to the specified torque in the order of number shown in the illustration.

Tightening torque: 23 ± 6 N.m (17 ± 4 ft-lb)

Scheme 19

Required Special Tool

1. MB992226: Serration Socket

Scheme 20

Scheme 21

Scheme 22

1. Set the special tool MB992226 to the pulley.
2. Set the closed wrench to the hexagonal area of the special tool MB992226.
3. Insert the hexagonal bit socket having width across flats of 10 mm into the hexagonal area of the rotor shaft.
4. Hold the pulley with the closed wrench. Rotate the rotor shaft clockwise to remove the pulley.

<< B >> FRONT BRACKET REMOVAL

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

Scheme 23

Scheme 24

1. Remove 6 installation screws of the stator lead wire, and then remove the stator.
2. Remove 4 installation screws of the regulator to remove the regulator 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. Unless inserting the wire to fix the brush, the rotor installation is difficult.

Scheme 25

Scheme 26

>> B << ROTOR INSTALLATION

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

Scheme 27

Scheme 28

Scheme 29

Scheme 30

1. Clean the inner race of the front bearing and that of the pulley.
2. Screws the inner race of the pulley until it touches the inner race of the front bearing.
3. Set the special tool MB992226 to the pulley.
4. Set the closed wrench to the hexagonal area of the special tool MB992226.
5. Insert the hexagonal bit socket having width across flats of 10 mm (0.4 inch) into the hexagonal area of the rotor shaft.
6. Hold the pulley with the closed wrench. Rotate the hexagonal bit socket counterclockwise to tighten it to the specified torque. Specified torque: 73 ± 12 N.m (54 ± 8 ft-lb)

Scheme 31

1. Set the special tool MB992226 to the pulley.
2. Fix the special tool MB9922226, with the glasses wrench to prevent the rotor shaft from rotating.
3. Lock the pulley when rotating it clockwise. Check that the pulley rotates smoothly when rotating it counterclockwise. CAUTION: Locking the one-way clutch might cause the damaged drive belt and an abnormal noise.

Scheme 32

Scheme 33

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: 2.0 - 2.3 ohms
2. Check the continuity between the slip rings and core.
3. If continuity is present, replace the rotor.

Scheme 34

Scheme 35

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 continuity, replace the stator.

RECTIFIER ASSEMBLY

Use the analog type tester to make sure the electrical continuity of each diode meets the table specification.

Unless the electrical continuity of each diode meets the table specification, replace the rectifier.

DIODE CONTINUITY TABLE

Scheme 36

Scheme 37

Scheme 38

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 (0.1 inch) minimum
2. Unsolder the lead of the brush. The brush will come out, becoming ready for removal.
3. Install a new brush by pushing it into the holder as shown in the illustration and soldering the lead.

See also:
• BATTERY CHECK
• DRIVE BELTS (FOR GENERATOR AND POWER STEERING OIL PUMP) (CHECK CONDITION)
• INSPECTION
• SYMPTOM CHART
• SYMPTOM CHART
• SYMPTOM CHART
• INSPECTION
• GENERAL SPECIFICATIONS
• SERVICE SPECIFICATIONS