service MITSUBISHI LANCER 2005 Owner's Guide

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Page 70 of 788

MITSUBISHI LANCER 2005 Owners Guide CHARGING SYSTEM
ENGINE ELECTRICAL16-6
7. Connect a tachometer or the MUT-II/III (Refer to
GROUP 11A − On-vehicle Service − Idle speed
check <4G1> P.11A-11 or GROUP 11C −
On-vehicle Service �

CHARGING SYSTEM
ENGINE ELECTRICAL16-6
7. Connect a tachometer or the MUT-II/III (Refer to
GROUP 11A − On-vehicle Service − Idle speed
check <4G1> P.11A-11 or GROUP 11C −
On-vehicle Service − Idle speed check <4G6>
P.11C-11).
8. Leave the hood open.
9. Check that the reading on the voltmeter is equal
to the battery voltage.
NOTE: If the voltage is 0 V, the cause is probably
an open circuit in the wire or fusible link between
the alternator "B" terminal and the battery (+)
terminal.
10.Turn the light switch on to turn on headlamps and
then start the engine.
11.Immediately after setting the headlamps 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: 70 % of normal current outputNOTE: .
•For the nominal current output, refer to the
Alternator Specifications.
•Because the current from the battery will soon
drop after the engine is started, the above step
should be carried out as quickly as possible in
order to obtain the maximum current output
value.
•The current output value will depend on the
electrical load and the temperature of the
alternator body.
•If the electrical load is small while testing, the
specified level of current may not be output
even though the alternator is normal. In such
cases, increase the electrical load by leaving
the headlamps turned on for some time to
discharge the battery or by using the lighting
system in another vehicle, and then test again.
•The specified level of current also may not be
output if the temperature of the alternator body
or the ambient temperature is too high. In such
cases, cool the alternator 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 alternator output wire is normal, remove
the alternator from the engine and check the
alternator.
13.Run the engine at idle after the test.
14.Turn the ignition switch to the "LOCK" (OFF)
position.
15.Remove the tachometer or the MUT-II/III.
16.Disconnect the negative battery cable.
17.Disconnect the ammeter and voltmeter.
18.Connect the negative battery cable.

Page 71 of 788

MITSUBISHI LANCER 2005 Owners Guide CHARGING SYSTEM
ENGINE ELECTRICAL16-7
REGULATED VOLTAGE TESTM1161001100354
This test determines whether the voltage regulator
correctly controlling the alternator output voltage.
1. Always be sure to

CHARGING SYSTEM
ENGINE ELECTRICAL16-7
REGULATED VOLTAGE TESTM1161001100354
This test determines whether the voltage regulator
correctly controlling the alternator output voltage.
1. Always be sure to check the following before the
test.
•Alternator installation
•Check that the battery installed in the vehicle is
fully charged.
(Refer to GROUP 54A − Battery − On-vehicle
Service − Charging P.54A-4).
•Drive belt tension
(Refer to GROUP 11A − On-vehicle Service <4G1>
P.11A-7 or GROUP 11C − On-vehicle Service
<4G6> P.11C-7.)
•Fusible link
•Abnormal noise from the alternator 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 Alternator test harness
(MB991519) to connect a digital voltmeter
between the alternator "S" terminal and earth
[Connect the (+) lead of the voltmeter to the "S"
terminal, and then connect the (-) lead of the
voltmeter to a secure earth or to the battery (-)
terminal].
5. Connect a clamp-type DC test ammeter with a
range of 0 − 120 A to the alternator "B" terminal
output wire.NOTE: The way of disconnecting the alternator
output wire and of connecting the ammeter is
possibly not found the problem that the output
current is dropping due to the insufficient
connection between terminal "B" and the output
wire.
6. Reconnect the negative battery cable.
7. Connect a tachometer or the MUT-II/III (Refer to
GROUP 11A − On-vehicle Service − Idle speed
check <4G1> P.11A-11 or GROUP 11C −
On-vehicle Service − Idle speed check <4G6>
P.11C-11).
8. Turn the ignition switch to the "ON" position and
check that the reading on the voltmeter is equal to
the battery voltage.
NOTE: If the voltage is 0 V, the cause is probably
an open circuit in the wire or fusible link between
the alternator "S" terminal and the battery (+)
terminal.
9. Turn all lamps and accessories off.
10.Start the engine.
11.Increase the engine speed to 2,500 r/min.
12.Read the value displayed on the voltmeter when
the alternator output current alternator becomes
10 A or less.
13.If the voltage reading conforms to the value in the
voltage regulation, then the voltage regulator is
operating normally.
AK300727AB
BatteryIgnition switch
Engine-ECU
Engine-A/T-ECU Ammeter (clamp-type)Load
Black MB991519
Voltmeter (digital-type) Red
YellowBlueAlternator B
FR
L
S
G

Page 76 of 788

MITSUBISHI LANCER 2005 Owners Guide CHARGING SYSTEM
ENGINE ELECTRICAL16-12
ALTERNATOR ASSEMBLY
REMOVAL AND INSTALLATION <4G1>M1161001400548
REMOVAL SERVICE POINT
<<A>> ALTERNATOR ASSEMBLY
REMOVAL
Remove the alternator assembly from abo

Page 77 of 788

MITSUBISHI LANCER 2005 Owners Guide CHARGING SYSTEM
ENGINE ELECTRICAL16-13
REMOVAL AND INSTALLATION <4G6>M1161001400559
Pre-removal Operation
•Under Cover Removal
•Strut Tower Bar Removal (Refer to GROUP 42 P.42-9).
•Drive Belt Re

Page 78 of 788

MITSUBISHI LANCER 2005 Owners Guide CHARGING SYSTEM
ENGINE ELECTRICAL16-14
REMOVAL SERVICE POINT
<<A>> SHIFT CABLE AND SHIFT CABLE
BRACKET ASSEMBLY REMOVAL
Remove the shift cable bracket installation bolt with
the shift cable installe

Page 80 of 788
CHARGING SYSTEM
ENGINE ELECTRICAL16-16
DISASSEMBLY SERVICE POINTS
<>FRONT BRACKET ASSEMBLY
REMOVAL
CAUTION
Do not insert the screwdriver blades too deep.
Doing so could damage the stator coil.
Insert the blades of screwdrivers between the front
bracket assembly and stator core, and pry and
separate them with the screwdrivers.
<>ALTERNATOR PULLEY REMOVAL
CAUTION
Perform operation carefully not to damage the
rotor.
Clamp the rotor in a vise with the pulley facing up to
remove the pulley.
<>STATOR / REGULATOR ASSEMBLY
REMOVAL
CAUTION
•Use a 180 − 250 W soldering iron, and finish
unsoldering within four seconds. Diodes will
be damaged by heat if unsoldering time is too
long.
•Avoid applying undue force to the diode
leads.
1. Unsolder the stator leads from the main diode of
the rectifier assembly when the stator is removed.
2. When removing the rectifier assembly from the
regulator assembly, undo the soldered points on
the rectifier assembly.
REASSEMBLY SERVICE POINTS
>>A< 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: Holding the brush with the wire facilities
installation of the rotor.
AK202718
AK202714
AK202778
Solder
Solder Rectifier
assembly
AB
AK202779
Wire
AB
AK202830
Rear bracket
Brush
Wire
AB

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 REMOVAL
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.
<> STARTER ASSEMBLY REMOVAL
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 <>7. Starter assemblyRemoval steps (Continued)

Page 86 of 788
STARTING SYSTEM
ENGINE ELECTRICAL16-22
REMOVAL AND INSTALLATION <4G6>M1162001000617
REMOVAL SERVICE POINT
<> STARTER ASSEMBLY REMOVAL
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).
•Under Cover Removal and Installation
AC304005
521
6
49 ± 9 N·m 18 ± 3 N·m9.0 ± 2.0 N·m
30 ± 3 N·m
AB
4
3
Removal steps
1. Starter cover
2. Starter connector and terminal
3. Clutch release cylinder connecting
bolts4. Clutch hose clamp
<>5. Starter assembly
6. Starter cover bracketRemoval steps (Continued)

Page 91 of 788
STARTING SYSTEM
ENGINE ELECTRICAL16-27
DISASSEMBLY SERVICE POINTS
<> MAGNETIC SWITCH REMOVAL
CAUTION
Do not clamp the yoke assembly with a vise.
Disconnect the lead from the M terminal of the
magnetic switch.
<> SNAP RING/STOP RING REMOVAL
1. Apply a long socket wrench of an appropriate size
to the stop ring and strike the wrench to drive out
the stop ring toward the pinion gear side.
2. Remove the snap ring with snap ring pliers, then
remove the stop ring and overrunning clutch.
STARTER MOTOR PARTS CLEANING
Never clean in a solvent such starter motor parts
as the magnetic switch, brush holder, and
armature. If they are soaked in a solvent, their
insulation could be impaired. When these parts
require cleaning, wipe off contamination with
cloth.
1. Never soak the drive unit in a solvent. If it is
washed in a solvent, the grease having been
packed in the overrunning clutch at the factory will
be washed out. Wipe the drive unit with cloth if it
requires cleaning.
REASSEMBLY SERVICE POINTS
>>A<< STOP RING/SNAP RING
INSTALLATION
Use a suitable puller to pull the stop ring until it gets
over the snap ring.
INSPECTION M1162001300157
COMMUTATOR
1. Support the armature with a pair of V block and
turn it to measure the runout of the surface not
rubbed by the brushes using a dial gauge.
Standard value: 0.05 mm or less
Limit: 0.1 mm
AK201882
B terminal
M terminal S terminal
AC
AK100883AC
Socket wrench
Stop ring
Pinion Gear
Overrunning
clutch
AK202791
Snap ring
pliersSnap ring
Pinion gear
Overrunning
clutch
AB
AK202911
Overrunning
clutchStop ring
Snap ring Stop ring
AB
AK202712

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