Motor MITSUBISHI LANCER 2005 Owner's Manual
[x] Cancel search | Manufacturer: MITSUBISHI, Model Year: 2005, Model line: LANCER, Model: MITSUBISHI LANCER 2005Pages: 788, PDF Size: 45.98 MB
Page 51 of 788
RADIATOR
ENGINE COOLING14-37
REMOVAL SERVICE POINT
<> RADIATOR UPPER
HOSE/RADIATOR LOWER HOSE
DISCONNECTION
Make mating marks on the radiator hose and the
hose clamp. Disconnect the radiator hoses.
INSTALLATION SERVICE POINT
>>A<< RADIATOR LOWER
HOSE/RADIATOR UPPER HOSE
CONNECTION
1. Insert radiator lower hose as far as the projection
of the cooling water inlet hose fitting.
2. Insert radiator upper hose as far as the projection
of the thermostat case assembly <4G1> or the
cooling water outlet hose fitting <4G6>.
3. Align the mating marks on the radiator hose and
hose clamp, and then connect the radiator hose.
12. Cooling fan motor & shroud
assembly
13. A/C condenser fan motor & shroud
assembly <4G6>
14. Radiator assembly
Cooling fan motor removal
steps
3. Radiator condenser tank hose
<> >>A<<5. Radiator upper hose
7. Cooling fan motor drive control unit
connector Radiator removal steps
12. Cooling fan motor & shroud
assembly
15. Cooling fan (L.H.)
16. Cooling fan (R.H.) <4G1 (Vehicles
with A/C)>
17. Cooling fan motor drive control unit
18. Cooling fan motor (L.H.)
19. Cooling fan (R.H.) motor <4G1
(Vehicles with A/C)>
20. Cooling fan shroudCooling fan motor removal steps
(Continued)
AC200641AC
Mating marks
AC200642
Mating marks
Projection
Cooling water hose fitting
or thermostat case assembly
AK
Radiator hose
Page 65 of 788
16-1
GROUP 16
ENGINE
ELECTRICAL
CONTENTS
CHARGING SYSTEM . . . . . . . .
16-2
GENERAL INFORMATION . . . . . .
16-2
SERVICE SPECIFICATIONS. . . . .16-3
SPECIAL TOOL . . . . . . . . . . . . . . .16-3
ON-VEHICLE SERVICE. . . . . . . . .16-3
ALTERNATOR OUTPUT LINE VOLTAGE
DROP TEST . . . . . . . . . . . . . . . . . . . . . 16-3
OUTPUT CURRENT TEST . . . . . . . . . . 16-5
REGULATED VOLTAGE TEST . . . . . . . 16-7
WAVEFORM CHECK USING AN
OSCILLOSCOPE . . . . . . . . . . . . . . . . . . 16-9
ALTERNATOR ASSEMBLY . . . . .16-12
REMOVAL AND INSTALLATION
<4G1> . . . . . . . . . . . . . . . . . . . . . . . . . . 16-12
REMOVAL AND INSTALLATION
<4G6> . . . . . . . . . . . . . . . . . . . . . . . . . . 16-13
DISASSEMBLY AND REASSEMBLY . . 16-15
INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-17
STARTING SYSTEM . . . . . . . . .16-19
GENERAL INFORMATION . . . . . .
16-19
SERVICE SPECIFICATIONS. . . . .16-20
STARTER MOTOR ASSEMBLY . .16-21
REMOVAL AND INSTALLATION
<4G1> . . . . . . . . . . . . . . . . . . . . . . . . . . 16-21
REMOVAL AND INSTALLATION
<4G6> . . . . . . . . . . . . . . . . . . . . . . . . . . 16-22
STARTER MOTOR ASSEMBLY
INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-23
DISASSEMBLY AND REASSEMBLY . . 16-26
INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-27
IGNITION SYSTEM . . . . . . . . . 16-30
GENERAL INFORMATION . . . . . .
16-30
SERVICE SPECIFICATIONS . . . . .16-31
SPECIAL TOOL . . . . . . . . . . . . . . .16-31
ON-VEHICLE SERVICE . . . . . . . . .16-32
IGNITION COIL (WITH BUILT-IN
POWER TRANSISTOR) CHECK . . . . . . 16-32
RESISTIVE CORD CHECK . . . . . . . . . . 16-32
SPARK PLUG CHECK AND
CLEANING <4G1> . . . . . . . . . . . . . . . . . 16-32
SPARK PLUG CHECK AND
CLEANING <4G6> . . . . . . . . . . . . . . . . . 16-33
CAMSHAFT POSITION SENSOR
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . 16-33
CRANK ANGLE SENSOR CHECK . . . . 16-33
DETONATION SENSOR CHECK . . . . . 16-33
IGNITION SECONDARY VOLTAGE
WAVEFORM CHECK USING AN
OSCILLOSCOPE . . . . . . . . . . . . . . . . . . 16-33
IGNITION COIL RELAY CHECK . . . . . . 16-37
IGNITION COIL . . . . . . . . . . . . . . . .16-38
REMOVAL AND INSTALLATION
<4G1>. . . . . . . . . . . . . . . . . . . . . . . . . . . 16-38
REMOVAL AND INSTALLATION
<4G6>. . . . . . . . . . . . . . . . . . . . . . . . . . . 16-39
CAMSHAFT POSITION SENSOR .16-40
REMOVAL AND INSTALLATION . . . . . . 16-40
CRANKSHAFT POSITION SENSOR16-41
REMOVAL AND INSTALLATION
<4G1>. . . . . . . . . . . . . . . . . . . . . . . . . . . 16-41
REMOVAL AND INSTALLATION
<4G6>. . . . . . . . . . . . . . . . . . . . . . . . . . . 16-42
DETONATION SENSOR . . . . . . . .16-43
REMOVAL AND INSTALLATION . . . . . . 16-43
Page 83 of 788
STARTING SYSTEM
ENGINE ELECTRICAL16-19
STARTING SYSTEM
GENERAL INFORMATIONM1162000100202
If the ignition switch is turned to the "START"
position, current flows in the pull-in and holding coils
provided inside magnetic switch, attracting the
plunger, When the plunger is attracted, the lever
connected to the plunger is actuated to engage the
starter clutch.
On the other hand, attracting the plunger will turn on
the magnetic switch, allowing the "B" terminal and
"M" terminal to conduct. Thus, current flows to
engage the starter motor.When the ignition switch is returned to the "ON"
position after starting the engine, the starter clutch is
disengaged from the ring gear.
An overrunning clutch is provided between the pinion
and the armature shaft, to prevent damage to the
starter.
SYSTEM DIAGRAM
AK202970
Pull-in coilHolding coil
Plunger
Lever
Pinion gear Overrunning clutch
Yo k e BrushArmature Ignition switch
Battery +
–
AB
B
M
S
Page 84 of 788
STARTING SYSTEM
ENGINE ELECTRICAL16-20
STARTER MOTOR SPECIFICATIONS
SERVICE SPECIFICATIONS
M1162000300068
Item 4G1 4G6
Type Reduction drive with planetary
gearReduction drive with planetary gear
Rated output kW/V 1.2/12 1.4/12
Number of pinion teeth 8 8
Item Standard value Limit
Pinion gap mm 0.5 − 2.0
−
Commutator run-out mm
−0.05
Commutator diameter mm 29.4 28.8
Undercut depth mm 0.5 0.2
Page 85 of 788
STARTING SYSTEM
ENGINE ELECTRICAL16-21
STARTER MOTOR ASSEMBLY
REMOVAL AND INSTALLATION <4G1>M1162001000628
REMOVAL SERVICE POINT
<> SHIFT CABLE AND SHIFT CABLE
BRACKET ASSEMBLY
Remove the shift cable bracket installation bolt with
the shift cable installed on the shift cable bracket,
and remove the shift cable and shift cable bracket
assembly from the transmission.
<> SHIFT CABLE CONNECTION
REMOVAL
Disengage the transmission, and remove the shift
cable assembly from the transmission.
<
Remove the starter assembly from above the
vehicle.
Pre-removal and Post-installation Operation
•Air Cleaner Assembly Removal and Installation (Refer to
GROUP 15 P.15-3).
•Battery and Battery Tray Removal and Installation
AC303962AB
1
1 2
3
56
7
4
30 ± 3 N·m18 ± 3 N·m
12 ± 2 N·m
Removal steps
1. Shift cable connection
<>2. shift cable and shift cable bracket
assembly
<>3. Shift cable connection 4. Starter connector and terminal
5. Harness bracket
6. Harness bracket <
Page 87 of 788
STARTING SYSTEM
ENGINE ELECTRICAL16-23
STARTER MOTOR ASSEMBLY INSPECTIONM1162001100205
PINION GAP ADJUSTMENT
1. Disconnect the field coil wire from the M-terminal
of the magnetic switch.
2. Connect a 12-volt battery between the S-terminal
and M-terminal.
CAUTION
This test must be performed quickly (in less than
10 seconds) to prevent the coil from burning.
3. Set the switch to "ON", and the pinion will move
out.
4. Check the pinion-to-stopper clearance (pinion
gap) with a feeler gauge.
Standard value: 0.5 − 2.0 mm5. If the pinion gap is out of specification, adjust by
adding or removing gasket(s) between the
magnetic switch and front bracket.
MAGNETIC SWITCH PULL-IN TEST
1. Disconnect the field coil wire from the M-terminal
of the magnetic switch.
CAUTION
This test must be performed quickly (in less than
10 seconds) to prevent the coil from burning.
2. Connect a 12-volt battery between the S-terminal
and M-terminal.
3. If the pinion moves out, the pull-in coil is good. If it
doesn't, replace the magnetic switch.
AK300648AB
<4G1>
Switch
S
M
Wire
Battery Starter
motor B
AKX01238
<4G6>
B MS
batterySwitch
Starter
motorWire
AG
AKX00198
Stopper
Pinion gap Pinion
AC
AKX00199
AK300649AB
<4G1>
S
M
Wire
Battery Starter
motor B
AKX01242
<4G6>
S
B M
Battery
Starter
motorWire
AF
Page 88 of 788
STARTING SYSTEM
ENGINE ELECTRICAL16-24
MAGNETIC SWITCH HOLD-IN TEST
1. Disconnect the field coil wire from the M-terminal
of the magnetic switch.
CAUTION
This test must be performed quickly (in less than
10 seconds) to prevent the coil from burning.
2. Connect a 12-volt battery between the S-terminal
and body.
3. Manually pull out the pinion as far as the pinion
stopper position.
4. If the pinion remains out, everything is in order. If
the pinion moves in, the hold-in circuit is open.
Replace the magnetic switch.
FREE RUNNING TEST
1. Place the starter motor in a vise equipped with
soft jaws and connect a fully-charged 12-volt
battery to the starter motor as follows:
2. Connect a test ammeter (100-ampere scale) and
carbon pile rheostat in series between the battery
(+) terminal and starter motor terminal.
3. Connect a voltmeter (15-volt scale) across the
starter motor.
4. Rotate the rheostat to full-resistance position.
5. Connect the battery cable from the battery (-)
terminal to the starter motor body.
6. Adjust the rheostat until the battery voltage shown
on the voltmeter is 11 V.
7. Confirm that the maximum amperage is within the
specifications and that the starter motor turns
smoothly and freely.
Current:
<4G1> maximum 95 Amps
<4G6> maximum 90 Amps
AK300650AB
<4G1>
S
BMWire
Battery Starter
motor
AKX01244
<4G6>
S
B M
Battery
Starter
motorWire
AF
AK300651AB
<4G1>
S
A M
V BCarbon-pile rheostat
Battery
VoltmeterAmmeter
Starter
motor
AKX01246
<4G6>
S
M
BAmmeter
Carbon-pile
rheostat
Battery
Starter
motor
Voltmeter
AF
A
V
Page 89 of 788
STARTING SYSTEM
ENGINE ELECTRICAL16-25
MAGNETIC SWITCH RETURN TEST1. Disconnect the field coil wire from the M-terminal
of the magnetic switch.
CAUTION
This test must be performed quickly (in less than
10 seconds) to prevent the coil from burning.
2. Connect a 12-volt battery between the M-terminal
and body.
WARNING
Be careful not to get your fingers caught
when pulling out the pinion.
3. Pull the pinion out and release. If the pinion
quickly returns to its original position, everything is
operating properly. If it doesn't, replace the
magnetic switch.
AK300652AB
<4G1>
S
BMWire
Battery Starter
motor
AKX01248
<4G6>
S
B M
Battery
Starter
motorWire
AF
Page 91 of 788
Page 247 of 788
ON-VEHICLE SERVICE
POWER STEERING37-13
STEERING WHEEL RETURN TO CENTRE
CHECK
M1372001800317
Conduct a road test:
1. Make both gradual and sudden turns and check
the steering wheel return.
2. At a vehicle speed of approximately 35 km/h, turn
the steering wheel 90°, hold a few seconds, then
release. If the steering wheel then returns 70° or
more, the return can be judged satisfactory.
NOTE: There will be a momentary feeling or
"heaviness" when the wheel is turned quickly, but
this is not abnormal (Oil pump discharge amount
is especially apt to be insufficient during idling).
DRIVE BELT TENSION CHECKM1372001900392
For vehicles with 1300 and 1600 engine, refer to
GROUP 11A, On-vehicle Service − Drive Belt
Tension Check P.11A-7.
For vehicles with 2000 engine, refer to GROUP 11C,
On-vehicle Service − Drive Belt Tension Check
P.11C-7.
FLUID LEVEL CHECKM1372002000284
1. Park the vehicle on a flat, level surface.
2. Start the engine, and then turn the steering wheel
several times to raise the temperature of the fluid
to approximately 50 − 60°C.
3. With the engine running, turn the wheel all the
way to the left and right several times.4. Check the fluid in the oil reservoir for foaming or
milkiness. Check the difference of the fluid level
when the engine is stopped, and while it is
running. If the change of the fluid level is 5 mm or
more, air bleeding should be done.
FLUID REPLACEMENTM1372002100333
1. Raise and support the front wheels.
2. Disconnect the return hose connection, and then
connect a vinyl hose to the return hose, and drain
the fluid into a container.
3. Disconnect the ignition coil connectors (Refer to
GROUP 16, Ignition Coil P.16-38or P.16-39).
4. While operating the starter motor intermittently,
turn the steering wheel all the way to the left and
right several times to drain all of the fluid.
5. Connect the return hose securely, and then
secure with the clip.
6. Fill the oil reservoir with specified fluid up to
between "MAX" and "MIN" marks, and then bleed
the air.
Specified fluid: ATF DEXRON III or DEXRON
II
POWER STEERING SYSTEM AIR
BLEEDING
M1372002200330
Perform air bleeding procedure as necessary after
replacing the steering gear or the steering fluid lines.
1. Raise and support the front wheels.
2. Disconnect the ignition coil connectors (Refer to
GROUP 16, Ignition Coil P.16-38 or P.16-39).
ACX01130
AB
70˚70˚
ACX01131While engine running While engine stoppedAC
Fluid level change: Within 5 mm
AC100369AB
Return hoseReturn hose
Vinyl hose