clutch MITSUBISHI LANCER EVOLUTION 2007 Service User Guide

ENGINE ELECTRICAL -Starting System16-22
DISASSEMBLY SERVICE POINTS
AA"MAGNETIC SWITCH REMOVAL
Disconnect field coil wire from “M” terminal of magnetic switch.
AB"ARMATURE/BALL REMOVAL
Caution
When removing the armature, take care not to lose the
ball (which is used as a bearing) in the armature end.
AC"SNAP RING/STOP RING REMOVAL
1. Press stop ring off snap ring with a suitable socket.
2. Remove snap ring with snap ring pliers and then remove
stop ring and overrunning clutch.
STARTER MOTOR PARTS CLEANING
1. Do not immerse parts in cleaning solvent. Immersing the
yoke and field coil assembly and/or armature will damage
insulation. Wipe motor assembly with a cloth only.
2. Do not immerse drive unit in cleaning solvent. Overrunning
clutch is pre-lubricated at the factory and solvent will wash
lubrication from clutch
3. The drive unit may be cleaned with a brush moistened
with cleaning solvent and wiped dry with a cloth.
“B” terminal“S” terminal
“M” terminalField coil
wire
Socket
Overrunning
clutch Stop ring
Pinion gear
Snap ring pliers
Overrunning
clutch Pinion gear Snap ring

ENGINE ELECTRICAL -Starting System16-23
REASSEMBLY SERVICE POINT
"AASTOP RING/SNAP RING INSTALLATION
Using a suitable pulling tool, pull overrunning clutch stop ring
over snap ring.
INSPECTION
COMMUTATOR CHECK
1. Place the armature in a pair of “V” blocks and check
the runout with a dial indicator.
Standard value: 0.05 mm
Limit: 0.1 mm
2. Measure the commutator outer diameter.
Standard value: 29.4 mm
Limit: 28.8 mm
3. Check the undercut depth between segments.
Standard value: 0.5 mm
Limit: 0.2 mm
BRUSH HOLDER CHECK
Confirm that the spring is activated when the brush is pressed
into the brush holder by hand.
Replace the brush holder if the spring is not activated.
Stop ringOverrunning
clutchStop ring
Snap ring
Undercut
Segment
Mica

ENGINE ELECTRICAL -Starting System16-24
OVERRUNNING CLUTCH CHECK
1. While holding clutch housing, rotate the pinion. Drive
pinion should rotate smoothly in one direction, but should
not rotate in opposite direction. If clutch does not function
properly, replace overrunning clutch assembly.
2. Inspect pinion for wear or burrs. If pinion is worn or burred,
replace overrunning clutch assembly. If pinion is damaged,
also inspect ring gear for wear or burrs.
FRONT AND REAR BRACKET BUSHING CHECK
Inspect bushing for wear or burrs. If bushing is worn or burred,
replace front bracket assembly or rear bracket assembly.
BRUSH REPLACEMENT
1. Check the surface contacting the commutator for
roughness and the brush length.
Limit value: 7.0 mm
2. If the limit is exceeded, replace the brush holder.
ARMATURE TEST
ARMATURE COIL SHORT-CIRCUIT TEST
1. Check that the armature coil is not grounded.
2. Place armature in a growler.
3. Hold a thin steel blade parallel and just above while rotating
armature slowly in growler. A shorted armature will cause
blade to vibrate and be attracted to the core. Replace
shorted armature.
ARMATURE COIL EARTH TEST
Check the insulation between each commutator segment and
armature coil core.
If there is no continuity, the insulation is in order.
Free
Lock
Length
Growler

CLUTCH 21A........................................................
CLUTCH OVERHAUL 21B............................................
21A-1
CLUTCH
CONTENTS

21A-2
CLUTCH
CONTENTS
GENERAL INFORMATION 3..................
SERVICE SPECIFICATIONS 3.................
LUBRICANTS 3..............................
ON-VEHICLE SERVICE 3.....................
Clutch Pedal Inspection and Adjustment 3........Bleeding 4.....................................
Clutch Pedal Position Switch Adjustment 4.......
CLUTCH PEDAL 5............................
CLUTCH CONTROL 7........................
Clutch Master Cylinder 9.......................

CLUTCH -General Information/Service Specifications/Lubricants/On-vehicle Service21A-3
GENERAL INFORMATION
The clutch is a dry single-disc, diaphragm type;
hydraulic pressure is used for the clutch control.
SERVICE SPECIFICATIONS
ItemsStandard value
Clutch pedal height mm202.1 - 206.1
173.5 - 177.5
Clutch pedal clevis pin play mm1-3
Clutch pedal free play mm4-13
Distance between the clutch pedal and the toeboard
when the clutch is disengaged mm114.3 or more
100 or more
LUBRICANTS
ItemsSpecified lubricantsQuantity
Clutch fluidBrake fluid DOT3 or DOT4As required
Push rod assemblyRubber grease
Boot
Release cylinder push rodMITSUBISHI genuine grease Part No.
0101011
ON-VEHICLE SERVICE
CLUTCH PEDAL INSPECTION AND
ADJUSTMENT
1. Turn up the carpet, etc. under the clutch pedal.
2. Measure the clutch pedal height and the clutch pedal
clevis pin play.
Standard value (A):
202.1 - 206.1 mm
173.5 - 177.5 mm
Standard value (B): 1 - 3 mm
Clutch pedal height

A
A
Clutch pedal
stopper
Clutch pedal clevis pin play
B

CLUTCH -On-Vehicle Service21A-4
3. If the height of the clutch pedal is outside the standard
value, loosen the setting nut to adjust the pedal height
to the standard value.
Caution
Do not push in the master cylinder push rod at this
time, otherwise the clutch will not operate properly.
4. After completing the adjustments, confirm that the clutch
pedal free play (measured at the face of the pedal pad)
and the distance between the clutch pedal (the face of
the pedal pad) and the clutch pedal stopper or toeboard
when the clutch is disengaged are within the standard
value ranges.
Standard value (C): 4 - 13 mm
Standard value (D):
114.3 mm or more
100 mm or more
5. If the clutch pedal free play and the distance between
the clutch pedal and the clutch pedal stopper or toeboard
when the clutch is disengaged do not agree with the
standard values, it is probably the result of either air in
the hydraulic system or a faulty master cylinder, clutch
cylinder or clutch. Bleed the air, or disassemble and inspect
the master cylinder, clutch cylinder or clutch.
6. Turn back the carpet, etc.
BLEEDING
Specified fluid: Brake fluid DOT 3 or DOT 4
Caution
Use the specified brake fluid. Avoid using a mixture
of the specified fluid and other fluid.
CLUTCH PEDAL POSITION SWITCH
ADJUSTMENT
1. Adjust the clutch pedal. (Refer to P. 21A-3).
2. Disconnect the connector from clutch pedal position
switch.
3. Loosen the clutch pedal position switch by rotating approx.
quarter turn to counterclockwise.
4. Fix the clutch pedal in full stroke.
Clutch pedal Setting nut
13±2 N·m
Clutch pedal clevis pin play
C


Clutch
pedal
stopper
D D

CLUTCH -On-Vehicle Service/Clutch Pedal21A-5
5. Fix the clutch pedal position switch by rotating approx.
quarter turn to clockwise in the position as shown in the
illustration.
6. Connect the connector to the clutch pedal position switch.
7. Check that the engine starts when the clutch is released.
CLUTCH PEDAL
REMOVAL AND INSTALLATION
Post-installation Operation
DClutch Pedal Adjustment (Refer to P.21A-2.)
DClutch Pedal Position Switch Adjustment (Refer to
P.21A-4.)
6713±2 N·m


1
12±2 N·m
8
11
2459
12±2 N·m
67
13±2 N·m
10 8
12 13
3145 910
1112 13
14
Full stroke
position of
clutch pedal
Approx.
3.5 mm

CLUTCH -Clutch Pedal21A-6
Removal steps
DColumn cover, under cover, lower
frame (Refer to GROUP 52A.)
1. Connector connection
2. Clutch pedal position switch
3. Clutch pedal position switch sub-har-
ness
4. Clip
5. Stopper
6. Snap pin7. Clevis pin
8. Clutch master cylinder mounting nut
9. Master cylinder member mounting bolt
10. Pedal pad
11. Pedal stopper
12. Clutch pedal assembly
13. Turn over spring
14. Bushing
INSPECTION
CLUTCH PEDAL POSITION SWITCH CONTINUITY
CHECK
1. Connect the circuit tester (Ωrange) to the connector of
clutch pedal position switch.
2. When the shaft is pushed more than the dimension as
shown in the illustration if there is not continuity, and
removing if there is continuity, the switch is good condition.
Continuity
2.5¶1mm
No continuity

CLUTCH -Clutch Control21A-7
CLUTCH CONTROL
REMOVAL AND INSTALLATION
Pre-removal Operation
Clutch Fluid DrainingPost-installation Operation
DClutch Fluid Supplying
DClutch Pedal Adjustment (Refer to P.21A-3.)
DClutch Pedal Position Switch Adjustment (Refer to
P.21A-4.)
DClutch Line Bleeding (Refer to P.21A-4.)

7
6
114
95 21
3 10
15±1 N·m
30±4 N·m
13±2 N·m
12±2 N·m
18±3 N·m
10
8
Specified grease:
MITSUBISHI genuine grease
Part No. 0101011
Release cylinder
push rodRelease fork
11
Clutch master cylinder removal
steps
1. Clevis pin assembly
2. Eye bolt
3. Gasket
4. Reservoir hose
5. Clevis pin and pushrod assembly con-
necting part
6. Clutch master cylinder
7. Sealer
8. Retainer assemblyClutch release cylinder removal
steps
10. Clutch pipe
11. Clutch release cylinder
Clutch line removal steps
9. Clutch hose
10. Clutch pipe