Generators & Regulators - Except Evolution: Diagnosis Mitsubishi Lancer IX

TROUBLE SHOOTING

1. Is battery in good condition? If Yes, then go to next step. If No, then charge or replace battery.
2. Is generator drive belt in good condition? If Yes, then go to next step. If No, then adjust belt tension or replace belt.
3. Does the generator malfunction light come on when the ignition switch is turned on? If Yes, then go to next step. If No: Check the ignition switch. Check for burnt-out generator malfunction light. Check the generator. Check the generator malfunction light-related circuits.
4. Does the generator malfunction light go out after starting the engine? If Yes, then go to next step. If No, check the generator.
5. Is an oscilloscope available? If Yes, then go to next step. If No, then go to step 7 .
6. Does the oscilloscope show a normal wave pattern? If Yes, then go to next step. If No, then check the generator.
7. Turn the engine on and idle at 2500 RPM. Turn the headlights on with the High Beams on. Be sure that there is voltage between generator terminal B and the positive battery terminal of 0.5V or less. Check that the voltage between the negative battery terminal and generator body is 0.5V or less. Are the generator output line and ground line in good condition? If Yes, then go to next step. If No, check the generator output line and ground line.
8. Is the output current normal? If Yes, then go to next step. If No, then check the generator.
9. Is the regulated voltage normal? If Yes, then go to next step. If No, then check the generator.
10. Is the voltage drop in the generator output line normal? If Yes, then generator is normal. Check other systems. If No, then check the output line.

GENERATOR OUTPUT LINE VOLTAGE DROP TEST

Required special tools: MB991502: Scan Tool MUT-II Sub Assembly.

This test determines whether the wiring from the generator B terminal to positive battery terminal (including the fusible link) is in good condition or not. (Scheme 2)

Scheme 2

1. Always be sure to check following before testing: Generator installation. Generator drive belt tension. Fusible link. Abnormal noise form generator while engine is running.
2. Tune ignition switch to LOCK (OFF) position.
3. Disconnect negative battery cable.
4. Disconnect the generator output wire from the generator B terminal and connect a DC test ammeter with a range of 0-100A in series between the B terminal and the disconnected output wire. (Connect the positive lead of the ammeter to the disconnected 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 MB991502.
8. Leave the hood open.
9. Start the engine.
10. With the engine running at 2500 RPM, 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 30A. Read the voltmeter. Voltage reading at or below limit value means voltage drop between generator and batter is OK. There should be a maximum voltage of 0.3V.
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 MB991502.
15. Disconnect the negative battery cable.
16. Disconnect the ammeter, voltmeter and engine tachometer.
17. Connect the generator output wire to the generator B terminal.
18. Connect the negative battery cable. Run the engine for 10 minutes at an idle after reconnecting negative battery cable.

OUTPUT CURRENT TEST

Required special tool: MB991502: Scan Tool MUT-II. This test determines whether the generator outputs normal current. For best results, use a charging system tester. If not available, follow the steps below. (Scheme 3)

Scheme 3

1. Before the test, always be sure to check the following. Generator installation. 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. Battery. Generator drive belt tension. 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 0-100A 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.)
5. Connect a voltmeter with a range of 0-20V 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 MB991502.
8. Leave the hood open.
9. Check to be sure that the reading on the voltmeter is equal to the battery positive voltage.
10. After turning on the headlights, start the engine.
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 RPM and read the maximum current output value displayed on the ammeter. Limit value: 70 percent of nominal current output.
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 MB991502.
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.

REGULATED VOLTAGE TEST

Required special tools

1. MB991502: Scan Tool MUT-II.
2. MB991519: Generator Harness Connector.

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

(Scheme 4)

Scheme 4

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. Generator drive belt tension. 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. Disconnect the generator output wire from the generator B terminal.
6. Connect a DC test ammeter with a range of 0-100A 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 MB991502.
9. Turn the ignition switch to the ON position and check that the reading on the voltmeter is equal to the battery positive voltage.
10. Check to be sure that all lights and accessories are off.
11. Start the engine.
12. Increase the engine speed to 2,500 RPM
13. Read the value displayed on the voltmeter when the current output by the generator becomes 10A or less.
14. 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. See «REGULATOR VOLTAGE SPECIFICATIONS TABLE»(ref-168345-S00272246752004110800000) .
15. After the test, lower the engine speed to idle.
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.

REGULATOR VOLTAGE SPECIFICATIONS