ignition MITSUBISHI LANCER 2006 Workshop Manual

AC200625
Cylinder block
drain plug
AC
ON-VEHICLE SER VICE
ENGINE COOLING14-22
5.App l y the designa ted sealant to t he scre w area of
th e cylin der block drain plu g , and then tighten to
th e st and ard torq ue.
Sp e c ified s ealant: 3 M Nut Loc king Part
No. 4171 o r e quivale n t
Ti ghtenin g torque:
40 ± 5 N⋅m <4G1>
44 ± 5 N⋅m <4G6>
6.Securely tighten t he drain plug of t he radiator .
7.Reinst all the ra diato r con denser t ank.
CAUTION
Do not use alcohol or methanol anti-freeze or any
engine coolants mixed with alcohol or methanol
anti-freeze. The use of an improper anti-freeze
can cause corrosion of the aluminium compo
-
nents.
AC303612AB
MB991871
AIR HOSE
8. By referring to the section on coolant, select an
appropriate concentration for safe operating
temperature within the range of 30 to 60%. Use
special tool LLC changer (MB991871) to refill the
coolant. A convenient mixture is a 50% water and
50% antifreeze solution (freezing point:
−31°C).
Recommended antifreeze: DIAQUEEN SUPER LONG LIFE COOLANT or equivalent
Quantity:
5.0 L <4G1>
7.0 L <4G6>
NOTE: For how to use special tool MB991871,
refer to its manufacturer’s instructions.
9. Reinstall the radiator cap.
10.Start the engine and let it warm up until the thermostat opens.
11.After repeatedly revving the engine up to 3,000 r/min several times, then stop the engine.
12.Remove the radiator cap after the engine has become cold, and pour in coolant up to the brim.
Reinstall the cap.
CAUTION
Do not overfill the radiator condenser tank.
13.Add coolant to the radiator condenser tank between the "F" and "L" mark if necessary.
CONCENTRATION MEASUREMENT
M1141001100352
Measure the temperature and specific gravity of the
engine coolant to check the antifreeze concentration.
Standard value: 30 − 60% (allowable concentra-
tion range)
Recommended antifreeze: DIAQUEEN SUPER
LONG LIFE COOLANT or equivalent
CAUTION
If the concentration of the anti-freeze is below
30%, the anti-corrosion property will be
adversely affected. In addition, if the concentra
-
tion is above 60%, both the anti-freezing and
engine cooling properties will decrease, affecting
the engine adversely. For these reasons, be sure
to maintain the concentration level within the
specified range.
COOLING FAN MOTOR DRIVE CONTROL
UNIT CHECK
M1141006100250
1. Remove the cooling fan motor drive control unit connector.
AC103195
Y1716AU
1
23
AC
Cooling fan motor
drive control unit
2. Turn the ignition switch to the "ON" position, and
measure the voltage between terminal 1 and 3 at
the harness side connector.
Standard value: system voltage

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 ASSEMB LY . . . . .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

CHARGING SYSTEM
ENGINE ELECTRICAL16-2
CHARGING SYSTEM
GENERAL INFORMATIONM1161000100522
The charging system uses the alternator output to
keep the battery charged at a constant level under
various electrical loads.
OPERATION
AKX00183
VoltageTime
Approximately
14.4 V
AC
Rota tion of the excited fi eld coil gene rates AC volt-
age in the sta t or .
This alternatin g cur r ent is rectified throu gh diodes to
DC volt
age h a ving a waveform sh own in t he illustra
-
tion.
The average outpu t volt a ge flu c tua t es slightly with
the alternato
r load con d ition.
When the ign i tion switch is t u rned on, current flows in
the field coil and initial e
x cit a tion of the field coil
occurs.
When the st ator coil beg ins to gen erate p o wer af ter
the eng
ine is st a r ted, th e fie l d coil is excited by th e
output
curren t of th e st ator coil.
The alternator outpu t volt a ge rises as th e fie l d cur-
rent increa ses and it falls a s the field cu rrent
decre
ases. Whe n the b a ttery volt a ge (alternato r "S"
terminal volt
ag e) reaches a regulated volt ag e of
approximately 14.4
V , the field current is cut o f f.
When th
e batte ry volt age drop s be low the regulated
volt
ag e, the volt ag e regulator re gulat es th e outp u t
volt
ag e to a const ant level by contro lling the field cur
-
rent.
In addition, when th e fie l d current is const a n t, the
altern
ator ou tput volt age rise s as the e ngine spe ed
increase
s .
SYSTEM DIAGRAM
AK400308
Alternator
B
Stator coil
Engine-ECU or
Engine-A/T-ECU
G
SL
FR
<4G1>
Voltage regulator Charge warning lightIgnition switch
Battery
Field coil
+
–
AB
AL TERNA T O R SPECIFICA T IONS
Item4G14G6
Ty p eBattery voltage sensing
Rated output V/A12/8012/110
Voltage regulatorElectronic built-in type

CHARGING SYSTEM
ENGINE ELECTRICAL16-4
2. Turn the ignition switch to the "LOCK" (OFF)
position.
3. Disconnect the negative battery cable.
4. 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 pos
-
sibly not found the problem that the output current
is dropping due to the insufficient connection
between terminal "B" and the output wire.
5. Connect a digital-type voltmeter between the
alternator "B" terminal and the battery (+)
terminal. [Connect the (+) lead of the voltmeter to
the "B" terminal and the connect the (-) lead of the
voltmeter to the battery (+) cable].
6. Reconnect the negative battery cable.
7. Connect a tachometer or the M.U.T.-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. 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 alternator 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 value displayed on the
voltmeter at this time.
Limit: maximum 0.3 V
NOTE: When the alternator 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 maxi
-
mum 0.4 V.
11.If the value displayed on the voltmeter is above
the limit value, there is probably a malfunction in
the alternator output wire, so check the wiring
between the alternator "B" terminal and the
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 lamps and the ignition switch.
14.Remove the tachometer or the M.U.T.-II/III.
15.Disconnect the negative battery cable.
16.Disconnect the ammeter and voltmeter.
17.Connect the negative battery cable.

CHARGING SYSTEM
ENGINE ELECTRICAL16-5
OUTPUT CURRENT TEST
M1161001000368
AK203362
Alternator
Ammeter
(clamp-type)
Voltmeter
Battery
Inition switch
Engine-ECU
or
Engine-A/T-ECU
Load
B FR
L
S
G
+
AH
–
Charging indicator
Brake warning light
This test determine s whethe r the a l terna t or outp u t
curren
t is normal.
1.Befo re the t e st, always be sure t o che c k the
fo llowi ng.
•Alternator inst allatio n
•Battery (Refer to GROUP 54 A − Battery − On-vehi-
cle Serv ice P.54A-5).
NOTE: The battery sh ould be sligh t ly discharg ed.
The
load neede d by a fully-charge d batte ry is
in
sufficient for an accurat e test.
•Drive belt tension
(Ref er to GROUP 1 1 A − On-vehicle Service <4G1>
P.11A-7 or GROUP 1 1 C − On-vehicle Se rvice
<4G6> P.11C-7.)
•Fusible link
• Abnormal noise from the altern ator while the
eng
ine is ru nning .
2.T u rn the ignition switch to the "LOCK" (OFF)
po sit i on.
3.Disco nnect the ne gative ba ttery cable.
CAUTION
Never use clips but tighten bolts and nuts to con-
nect the line. Otherwise loose connections (e.g.
using clips) will lead to a serious accident
because of high current.
4. 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 pos
-
sibly not found the problem that the output current
is dropping due to the insufficient connection
between terminal "B" and the output wire.
5. Connect a voltmeter with a range of 0 − 20 V
between the alternator "B" terminal and the earth
[Connect the (+) lead of the voltmeter to the "B"
terminal, and then con nect the (-) lead of the
voltmeter to the earth].
6. Connect the negative battery cable.
7. Connect a tachometer or the M.U.T.-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.

CHARGING SYSTEM
ENGINE ELECTRICAL16-6
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 (+) ter
-
minal.
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 output
NOTE: .
•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 dis
-
charge the battery or by using the lighting sys-
tem 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 M.U.T.-II/III.
16.Disconnect the negative battery cable.
17.Disconnect the ammeter and voltmeter.
18.Connect the negative battery cable.

CHARGING SYSTEM
ENGINE ELECTRICAL16-7
REGULATED VOLTAGE TEST
M1161001100860
AK300727AC
BatteryIgnition switch
Engine-ECU
Engine-A/T-ECU Ammeter (clamp-type)
Load
Blue
MB991519
Voltmeter (digital-type)Red
Yellow BlackAlternator
B
FR
L
S
G
This test determine s whethe r the volt age regulator
correctly con
t rolling t he alternato r outpu t volt a ge.
1.Always b e su re to check the following b e fore th e
te st.
•Alternator inst allatio n
•Check that the b a ttery inst a lled in th e ve hicle is
fully charg
ed.
(Refer to GROUP 54A − Battery − On-vehicle Service −
Charging
P.54A - 4).
•Drive belt tension
(Ref er to GROUP 1 1 A − On-vehicle Service <4G1>
P.11A-7 or GROUP 1 1 C − On-vehicle Se rvice
<4G6> P.11C-7.)
•Fusible link
•Abnormal noise from the a l tern ator while the
eng
ine is ru nning
2.T u rn the ignition switch to the "LOCK" (OFF)
po sit i on.
3.Disco nnect the ne gative ba ttery cable.
4.Use the special tool Alternat or test harne ss
(MB99151 9) to connect a d i git a l voltmet e r
be tween the alte rnator "S" te rmin al an d earth
[Con nect the (+) lead o f the voltmeter t o the "S"
terminal, and then con nect the (-) lead of the
voltmeter to a secure earth or to the battery (-)
te rmin al].
5.Conn ect a clamp-t y pe DC test ammete r with a
ran ge of 0
− 120 A to the alte rnator "B" te rmin al
ou
tput wire
.
NOTE: The way of d i sconnectin g the a l terna t or
o
u
tput wire an d o f conn ecting the ammete r is pos
-
sibl y no t fo und th e p r oblem th at t he outp u t cur r ent
is dro
ppin g due t o the insu fficient conne ction
b
e tween te rmin al "B" an d the o u tput wire.
6.Reconne ct the negat ive battery ca ble.
7.Conn ect a t a chometer or th e M.U.T . -II/III (Refe r to
GROUP 1 1 A
− On-veh icle Service − Idle speed
check <4G1>
P.11A - 11 or GROUP 1 1 C −
On-vehicle Service − Idle speed check <4G6>
P.11C-11).
8. T u rn the ignition switch to the "ON" position an d
ch ec k t h at th e rea d i n g on t h e vo lt me te r i s eq u a l t o
th e batte ry volt age.
NOTE: If the volt a ge is 0 V , the cause is proba bly
a
n
open circuit in th e wire or fusible link betwee n
th
e alt
e
rnator "S" t e rminal a nd the battery (+) ter
-
minal.
9.T u rn all lamp s and accessorie s of f.
10.St a r t the en gine .
11 . I ncre ase t he eng ine speed to 2,5 00 r/min.
12.Read the va lue disp layed on the voltmeter when
th e alt e rnator output curren t alte rnator b e comes
1 0 A or le ss.
13.If the volt age re adin g conf orms t o the va lue in the
volt age regulation , then the volt age re gula t or is
o perating normally .

CHARGING SYSTEM
ENGINE ELECTRICAL16-8
If the voltage is not within the standard value,
there is a malfunction of the voltage regulator or of
the alternator.
14.After the test, lower the engine speed to the idle speed.
15.Turn the ignition switch to the "LOCK" (OFF) position.
16.Remove the tachometer or the M.U.T.-II/III.
17.Disconnect the negative battery cable.
18.Disconnect the ammeter and voltmeter.
19.Connect the alternator output wire to the alternator "B" terminal.
20.Remove the special tool, and return the connector
to the original condition.
21.Connect the negative battery cable.
Voltage Regulation Table
Standard value:
Inspection terminalVoltage regulator ambient
temperature
°C
Voltage V
Terminal "S"−2014.2 − 15.4
2013.9 − 14.9
6013.4 − 14.6
8013.1 − 14.5

STARTING SYSTEM
ENGINE ELECTRICAL16-19
STARTING SYSTEM
GENERAL INFORMATIONM1162000100202
If the ignition switch is turned to the "START" posi-
tion, current flows in the pull-in and holding coils pro-
vided 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" posi-
tion after starting the engine, the starter clutch is dis-
engaged 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
Brush Armature
Ignition switch
Battery
+
–
AB
B
M S

IGNITION SYSTEM
ENGINE ELECTRICAL16-30
IGNITION SYSTEM
GENERAL INFORMATIONM1163000100294
This system is equipped with two ignition coils (A and
B) with built-in power transistors for the No. 1 and
No. 4 cylinders and the No. 2 and No. 3 cylinders
respectively.
Interruption of the primary current flowing in the pri-
mary side of ignition coil A generates a high voltage
in the secondary side of ignition coil A. The high volt
-
age thus generated is applied to the spark plugs of
No. 1 and No. 4 cylinders to generate sparks. At the
time that the sparks are generated at both spark
plugs, if one cylinder is at the compression stroke,
the other cylinder is at the exhaust stroke, so that
ignition of the compressed air/fuel mixture occurs
only for the cylinder which is at the compression
stroke.
In the same way, when the primary current flowing in
ignition coil B is interrupted, the high voltage thus
generated is applied to the spark plugs of No. 2 and
No. 3 cylinders.
The engine-ECU or engine-A/T-ECU
turns the two power transistors inside the ignition
coils alternately on and off. This causes the primary
currents in the ignition coils to be alternately inter
-
rupted and allowed to flow to fire the cylinders in the
order 1-3-4-2.
The engine-ECU or engine-A/T-ECU
determines which ignition coil should be controlled
by means of the signals from the camshaft position
sensor which is incorporated in the camshaft and
from the crank angle sensor which is incorporated in
the crankshaft. It also detects the crankshaft position
in order to provide ignition at the most appropriate
timing in response to the engine operation condi
-
tions. It also detects the crankshaft position in order
to provide ignition at the most appropriate timing in
response to the engine operation conditions.
When the engine is cold or operated at high alti-
tudes, the ignition timing is slightly advanced to pro-
vide optimum performance.
When the automatic transmission shifts gears, the
ignition timing is also retarded in order to reduce out
-
put torque, thereby alleviating shifting shocks.
SYSTEM DIAGRAM
AK101074
Air flow sensor
<4G6> MAP sensor <4G1>
Intake air temperatur
sensor
Engine coolant
temperature sensor
Camshaft position
sensor
Crank angle sensor
Barometric pressure
sonsor <4G6>
Detonatoin sensor
Ignition switch-ST Engine-A/T-
ECU Engine-ECU

Ignition coil B
Cylinder No. 23 4
AG
1
Spark plug Ignition coil A
Ignition
switch
Battery