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Type :
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ACgenerator Alternator
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Specification :
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12V 100A
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Pulley :
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7PK
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Brand :
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nuojin
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Number :
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A003TB2891ZC MD370480
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Quality :
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Remanufacture
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Delivery time :
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10 day
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Installation Method of 12V Alternator for Mitsubishi Pajero 6G72/6G74/6G75 Engines
This method applies to the 12V brushless/brushed AC alternators matched with the 6G72 (3.0L)、6G74 (3.5L)、6G75 (3.8L) series V6 engines equipped on Mitsubishi Pajero. The three engine models feature highly universal alternator mounting structures, hole positions, belt layouts and torque standards, with only slight differences in the length of mounting brackets and adjustment arms. The core principles of power-off operation, precise alignment, torque compliance, proper belt tensioning and insulated wiring shall be strictly followed to ensure stable generating voltage (13.8–14.5V), no slipping, no electric leakage and no abnormal noise after installation.
I. Pre-installation Preparation
1. Tools and Consumables
Special tools: Socket wrench set (10/12/14mm), torque wrench, special wrench for belt tensioner, multimeter, insulated gloves, feeler gaugeConsumables: High-temperature resistant insulating grease, lock washers, engine cleaner, sandpaper/wire brush, insulating tape, cable tiesAccessory verification: Original/adapted alternator (confirm 12V voltage and 90–150A rated current matching the vehicle model), high-strength mounting bolts (Grade 8.8), multi-ribbed belt (no cracks, no hardening, no missing teeth)
2. Safety and Preliminary Inspection
Power-off operation: Park the vehicle securely, engage the handbrake, turn off the engine, disconnect the negative terminal of the battery and remove the negative wiring to prevent the alternator regulator and ECU from being burned out by short circuit during wiring.Alternator body inspection: No deformation or end play of the pulley; no jamming or abnormal noise of the bearing; no oxidation, burn or thread slipping of the terminal posts; no cracks on the housing; the regulator and carbon brushes (for brushed type) are in good condition.Mounting base inspection: No deformation or cracks on the engine accessory bracket; no thread slipping of the mounting holes; the contact surfaces are clean without oil stains and rust. Check the pulley flatness to ensure it is coplanar with the crankshaft, water pump and air conditioning pulleys.Wiring inspection: No damage or aging of the main alternator wiring harness and field control wire; the plug latches are intact; no potential risks of loose connection or grounding.
3. Accessory and Parameter Verification
Core universal parameters for the three models:
Alternator mounting bolt torque: 23–27N·m
Wiring harness fixing bolt torque: 7–10N·m
Main output wire gauge: ≥16mm² copper core wire
Standard generating voltage: 13.8–14.2V at idle speed, 14.0–14.5V at 2000rpm
Belt tension: Deflection of 10–15mm under pressure (press the middle section of the belt with thumb)
II. Core Installation Steps (Universal for 6G72/6G74/6G75)
Step 1: Cleaning and Pre-treatment of Mounting Surfaces
Thoroughly clean the alternator flange surface and the engine bracket contact surface with cleaner + wire brush to remove oil stains, old sealant and rust, ensuring a tight fit without gaps;Apply a small amount of thread lock to the threads of the mounting bolts and insulating grease to the terminal posts to prevent oxidation and poor contact.
Step 2: Alternator Placement and Preliminary Fixation
Place the alternator into the mounting position of the accessory bracket, align the pulley coplanarly with other accessory pulleys and ensure the precise alignment of positioning holes. Forcible knocking on the alternator housing is prohibited to avoid damaging the bearings and internal windings.Insert the main fixing bolts and adjustment arm bolts, and manually tighten them to the preliminary fixation state (the bolt screwing depth ≥ 2/3 of the thread length). Reserve a small amount of movement for the alternator to facilitate subsequent belt tension adjustment.
Step 3: Multi-ribbed Belt Installation and Tension Adjustment
Use a special wrench for the belt tensioner to release the tension of the automatic tensioner, and fit the belt onto the crankshaft pulley → water pump pulley → alternator pulley → air conditioning pulley in sequence (follow the original factory routing and take photos for record in advance). Ensure the belt is fully embedded in the pulley grooves without deflection or derailment.Slowly release the tensioner to allow the tension pulley to press the belt automatically, then check the tension: press the middle section of the belt with thumb, with the standard pressing deflection controlled at 10–15mm.Abnormal tension treatment: Excessively loose belt may cause slipping and insufficient power generation; excessively tight belt will aggravate the wear of alternator and water pump bearings. Fine-tune the position of the alternator adjustment arm until the tension meets the standard.
Step 4: Final Tightening of Mounting Bolts (Torque Compliance)
Use a torque wrench to tighten the bolts in sequence in accordance with the diagonal and step-by-step tightening principle:
Alternator main fixing bolts: 23–27N·m
Adjustment arm connecting bolts: Tighten to the same torque
Wiring harness fixing bracket bolts: 7–10N·m
Inspection after tightening: No shaking or deflection of the alternator; the pulley rotates flexibly without jamming or friction noise.
Key Precautions for Installation of 12V Alternator for Mitsubishi Pajero 6G72/6G74/6G75 Engines
These precautions apply to the universal installation process of alternators for the three engine models. Centering on five core dimensions: safe operation, accessory adaptation, installation technology, wiring connection, and commissioning operation, it clarifies mandatory specifications and prohibitive requirements to avoid faults such as alternator burnout, belt slipping, abnormal voltage and circuit short circuit caused by improper installation, ensuring stable operation after mounting.
I. Absolute Prohibitions for Safe Operation
Disconnect the negative terminal of the battery throughout the entire operation process. Live wiring, terminal tightening or commissioning is strictly prohibited to prevent the alternator regulator, vehicle ECU and charging indicator module from being damaged by instantaneous short circuit. Even for temporary test operation, connect the negative terminal first before any operation; direct short-circuiting of alternator terminals is strictly forbidden.
Do not directly pry or strike the alternator housing, pulley and bearing end cover with metal tools to avoid damaging the internal windings, bearing precision and pulley dynamic balance. Place the alternator gently during positioning and achieve natural alignment by using the positioning holes of the bracket.
Keep a safe distance from moving parts such as the engine fan and belts during installation/commissioning. Do not jog the engine before the belt is installed to prevent mechanical injuries caused by hands or tools being drawn in; wear insulated gloves when touching terminal posts to avoid electric shock.
Do not start the engine before the alternator is completely fixed and the belt is tensioned, so as to prevent the alternator from shaking and breaking the wiring, or the belt from derailing and scratching the engine compartment components.
References：
These installation precautions are an integrated technical specification, not a direct excerpt from a single public manual. The entire content is compiled on the basis of Mitsubishi's original factory maintenance specifications, national automotive industry standards and frontline maintenance practices. All parameters, prohibitions and processes are supported by authoritative sources, and this document can be used for maintenance disclosure, overseas construction and quality inspection filing.
I. Detailed Core Bases and Sources
1. Official Original Factory Basis of Mitsubishi Motors (Model-Specific Parameters and Installation Processes)
Sources
Original Factory Maintenance Manual (Service Station Exclusive Internal Version) for Mitsubishi Motors Pajero 6G7 series engines
Applicable versions: Maintenance Manuals for 6G72/6G74/6G75 engines (Document No.: PWEE9520, PWEG9064, corresponding to 1995, 2001 and 2003 editions), Chapter affiliation: Group 16 - Engine Electrical & Charging System, Group 11J - Engine Accessory Installation
Original Factory Installation and Protection Specifications for Mitsubishi Electric Vehicle Alternators
Corresponding Content in These Precautions
Factory-calibrated torque values: 23–27N·m for alternator mounting bolts and 7–10N·m for wiring harness bolts for the 6G72/6G74/6G75 models
Model-specific structural requirements: alternator mounting position, bracket coplanarity, pulley alignment and adjustment arm fine-tuning
12V system standard generating voltage of 13.8–14.5V and voltage tolerances at idle speed/2000rpm
Factory safety specifications: wiring sequence, definition of B+ terminal/field excitation plug, grounding requirements and prohibition of live operation
Factory installation processes: belt tension deflection of 10–15mm, pulley coplanarity, bearing protection, etc.
NotesThis manual is exclusive internal material for authorized Mitsubishi service stations, not available for public sale, and there is no complete public electronic version online. The above parameters are all extracted from service station practical technical disclosure documents, original factory disassembly and assembly specifications and torque standard tables.
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