alternator MITSUBISHI LANCER EVOLUTION 2007 Service Owner's Manual

MPI -Troubleshooting13A-64
OK
To the next page
OK
Measure at the C-39 engine-ECU connector.
DMeasure the engine-ECU terminal voltage.
DEngine: Idling
DA/C switch: ON (A/C compressor driven state)
DVoltage between terminal No .24 and earth
(A/C setting temperature: Minimum temperature)
(Air volume: Maximum)
OK:1 V or less
(A/C setting temperature: indoor temperature)
(Air volume: Minimum)
OK:System voltageNGCheck the Inspection Procedure 28: A/C load signal system.
(Refer to P.13A-95.)
NG
Replace the alternator.
OK
Check the trouble symptoms.OKIntermittent malfunction
(Refer to GROUP 00 - Points to Note
for Intermittent Malfunctions.) NG
OK
Check the harness between the
alternator and engine-ECU.
DCheck for disconnection,
short-circuit and damage of the
output cable.Repair
OK
Measure at the C-40 engine-ECU
connector.
DMeasure the engine-ECU terminal
voltage.
DEngine: Idling (after warm-up)
DRadiator fan: Stopped
DVoltage between terminal No. 33
and earth
OK:Voltage rises 0.2 to 3.5 V when
headlamp is turned OFF and
ON.
DVoltage between terminal No. 41
and earth
OK:Voltage drops whenheadlamp
is turned OFF and ON.NGCheck the following connectors:
C-40, B-21, B-03NG
Repair
OK
Check the harness between the
engine-ECU and earth joint.
DCheck for disconnection and
damage of the earth cable.
(2) NGCheck the following connector:
C-39NG
Repair
NG
Replace the engine-ECU.
OK
Check the trouble symptoms.OKIntermittent malfunction
(Refer to GROUP 00 - Points to Note
for Intermittent Malfunctions.) NG
OK
Check the harness between the
engine-ECU and battery.
DCheck for disconnection,
short-circuit and damage of the
power cable.Repair
OK
Measure at the C-115 and C-126
engine-ECU connectors.
DMeasure the engine-ECU terminal
voltage.
(1) Voltage between terminal No. 80
and earth
OK:System voltage
(2) Voltage between terminal No. 13
and earth
Voltage between terminal No. 26
and earth
(Ignition switch: ON)
OK:0.5 V or less(1) NGCheck the following connectors:
C-115, C-129, C-05, C-135NG
Repair
OK
MUT-IIData list
DNo. 59: Oxygen sensor (rear)
(Refer to P.13A-105.)NGCheck the Code No. P0136: Oxygen sensor (rear) system.
(Refer to P.13A-27.)
From the previous page

MPI -Troubleshooting13A-77
Inspection Procedure 18
Battery dies
Probable cause
Causes shown on right are suspected.DBattery malfunction
DG terminal short - circuit
DAlternator malfunction
DEngine-ECU malfunction
OK
To the next page
OK
Check the following connector:
C-122NG
Repair
OK
Replace the alternator.NG
OK
Check the harness between the
alternator and ignition switch.
DCheck for damage of the power
cable.Repair NG
OK
Check the harness between the
alternator intermediate connector and
alternator.
DCheck for disconnection and
short-circuit of the power cable.Repair NG
OK
Check the harness between the
alternator intermediate connector and
alternator.
DCheck for short-circuit of the output
cable.Repair
OK
Measure at the B-14 alternator
intermediate connector.
DDisconnect the connector to
measure at the male connector
side.
DIgnition switch: ON
DVoltage between terminal No. 10
and earth
OK:System voltageNGCheck the following connector:
B-22NG
Repair
OK
Check and repair the harness between
the alternator intermediate connector
and ignition switch.
DCheck for disconnection and
short-circuit of the power cable.
OK
Measure at the B-14 alternator
intermediate connector.
DDisconnect the connector to
measure at the female connector
side.
DIgnition switch: ON
DVoltage between terminal No. 9 and
earth
OK:System voltageNGCheck the following connectors:
C-130, C-01, C-213, C-29 drive vehicles>NG
Repair
OK
Check the following connector:
B-14NG
Repair
Check the battery.
(Refer to GROUP 54 - Battery.)NGReplace the battery.

MPI -Troubleshooting13A-78
NG
Replace the engine-ECU.
OK
Check the trouble symptoms.OKIntermittent malfunction
(Refer to GROUP 00 - Points to Note
for Intermittent Malfunctions.)
OK
Measure at the C-122 engine-ECU
connector.
DMeasure the engine-ECU terminal
voltage.
DEngine: Idling (after warm-up)
DRadiator fan: Stopped
DVoltage between terminal No. 33
and earth
OK:Voltage rises 0.2 to 3.5 V
when headlamp is turned
OFF and ON.NGCheck the charging device.
(Refer to GROUP 16 - Charging
Device.)
OK
Measure at the C-122 engine-ECU
connector.
DDisconnect the connector to
measure at the harness side.
DIgnition switch: ON
DVoltage between terminal No. 33
and earth
OK:System voltageNGCheck and repair the harness between
the alternator intermediate connector
and engine-ECU.
DCheck for short-circuit of output
cable.
From the previous page

MPI -Troubleshooting13A-110
Terminal No.Normal condition Check condition (Engine condition) Check item
12Power supplyIgnition switch: “ON”System voltage
25
19Air flow sensor reset
signal
Engine: Idle operation0-1V
signal
Engine speed: 3,000 r/min6-9V
21Fan controllerRadiator fan is not operating0 - 0.3 V
Radiator fan is operating0.7 V or more
22Fuel pump relay 2Ignition switch: “ON”System voltage
Engine: Idle operation1 V or less
24A/C load signalDEngine:
Idle operation
DA/C switch: ON
(A/C compressor
runs)DOutdoor air
sensor ambient
temperature:
18_C or more
DA/C setting
temperature:
Minimum
temperature
DA/C air volume:
Maximum1 V or less
DA/C setting
temperature:
indoor
temperature
DA/C air volume:
MinimumSystem voltage
32Condenser fan motor
relay (HI)Fan inactive state
(Engine coolant temperature: 90_C or less)System voltage
Fan high-speed rotation state
(Engine coolant temperature: 105_C or more)1 V or less
33Alternator G terminalDEngine: After warm-up, idle operation
DRadiator fan: Not operating
DHeadlamp: OFF→ON
DStop lamp: OFF→ON
DRear defogger switch: OFF→ONVoltage increases by
0.2 - 3.5 V
34Condenser fan motor
relay (LOW)Fan inactive state
(Engine coolant temperature: 90_C or less)System voltage
Fan low-speed rotation state (Engine coolant
temperature: 95 - 100_C or more)1 V or less
35Intercooler water
spraylamp
Ignition switch: “ON”System voltage
spraylamp
Ignition switch: “LOCK” (OFF)1 V or less
36Engine warning lampIgnition switch: “LOCK” (OFF)→“ON”1 V or less→System
voltage (After several se-
conds have elapsed)

MPI -Troubleshooting13A-111
Terminal No.Normal condition Check condition (Engine condition) Check item
37Power steering fluid
pressure switchEngine: Idling after
warming upWhen steering wheel
is stationarySystem voltage
When steering wheel
is turned1 V or less
38Engine control relayIgnition switch: “LOCK” (OFF)System voltage
Ignition switch: “ON”1 V or less
39Fuel pump relay 3While engine is idling, suddenly depress the
accelerator pedal.Temporarily rises slightly
from 1 V or less.
41Alternator FR
terminalDEngine: After warm-up, idle operation
DRadiator fan: Not operating
DHead lamp: OFF→ON
DStop lamp: OFF→ON
DRear deffogger switch: OFF→ONVoltage decrease
44Intercooler water
spray switch (Auto)DIgnition switch: “ON”
DIntercooler water spray switch: ON1 V or less
DIgnition switch: “ON”
DIntercooler water spray switch: OFFSystem voltage
45A/C switchEngine: Idle operationTurn the A/C switch
OFF0.5 V or less
DA/C switch: ON
DA/C setting
temperature
When room tem-
perature is 25_C
or more: Max
Cool
When room tem-
perature is 25_C
or less: Max. HotSystem voltage
53Secondary air control
solenoid valveIgnition switch: “ON”System voltage
54Oxygen sensor
heater(Rear)
Engine: Idling after warming up1 V or less
heater(Rear)
Engine speed: 5,000r/minSystem voltage
55Intercooler water
sprayrelay
Ignition switch: “ON”System voltage
spray relay
Ignition switch: “LOCK” (OFF)1 V or less
58Tachometer signalEngine speed: 3,000r/min0.3 - 3.0 V
60Oxygen sensor
heater(front)
Engine: Idling after warming up1 V or less
heater(front)
Engine speed: 5,000r/minSystem voltage
71Ignition switch - STEngine: Cranking8 V or more

ENGINE COOLING -Water Pump14-13
WATER PUMP
Caution
If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact
the parts or tools to the caliper because the paint of caliper will be scratched.
REMOVAL AND INSTALLATION
Pre-remobal and Post-installation Operation
DEngine Coolant Draining and Supplying (Refer to P.14-6.)
DTiming Belt Removal and installation (Refer to GROUP 11A.)
1
Bolt specifications
28×22
2
23±3 N·m
14±1 N·m
Nominal diameter×Nominal length mm
8×70
8×14
8×22 8×25
3 4
22±4 N·m
Removal steps
1. Alternator brace
2. Water pump
3. Water pump Gasket
"AA4. O-ring
INSTALLATION SERVICE POINT
"AAO-RING INSTALLATION
Fit an O-ring into the O-ring groove located at the end of
the water inlet pipe and apply water to the O-ring or the
inside of the mounting surface of the water pump for insertion.
CAUTION
Do not let the O-ring get contaminated with grease, such
as engine oil.Water pump
O-ring
Water inlet pipe

INTAKE AND EXHAUST -Intake ManifoldINTAKE AND EXHAUST -Intake Manifold15-17
28 2325
26
2719
20 2221
23
24
30
23
29
20±2 N·m
20±2 N·m5.0±1.0 N·m
20±2 N·m
9.0±1.0 N·m
22±4 N·m 20±2 N·m 36±6 N·m
9.0±1.0 N·m
31±3 N·m 9.0±1.0 N·m 11±1 N·m
19. Vacuum hose
20. Fuel pressure solenoid valve
21. PCV hose
DAlternator (Refer to GROUP 16.)
22. Vacuum hose and Vacuum pipe
assembly connecting bolt
23. Vacuum tank, EGR solenoid valve,
Secondary air control solenoid
valve, Vacuum hose assembly24. Intake manifold stay
25. EGR valve
26. EGR gasket
27. Alternator brace stay
28. Intake manifold
29. Intake manifold gasket
30. Purge control solenoid valve
assembly
REMOVAL SERVICE POINTS
AA"DELIVERY PIPE, INJECTOR AND FUEL
PRESSURE REGULATOR ASSEMBLY REMOVAL
The delivery pipe must be removed with the injector and
fuel pressure regulator attached.
Caution
Take care not to drop delivery pipe, injector, or fuel
pressure regulator assembly when removing those parts.

16-1
ENGINE
ELECTRICAL
CONTENTS
CHARGING SYSTEM 2................
GENERAL INFORMATION 2................
SERVICE SPECIFICATIONS 3...............
SPECIAL TOOL 3..........................
ON-VEHICLE SERVICE 4...................
Alternator Output Line Voltage Drop Test 4......
Output Current Test 5........................
Regulated Voltage Test 7.....................
Waveform Check Using An Analyzer 8..........
ALTERNATOR 10..........................
STARTING SYSTEM 17................
GENERAL INFORMATION 17...............
SERVICE SPECIFICATIONS 17..............
ON-VEHICLE SERVICE 18..................
STARTER 18..............................
IGNITION SYSTEM 26.................
GENERAL INFORMATION 26...............
SERVICE SPECIFICATIONS 27..............
SPECIAL TOOL 27.........................
ON-VEHICLE SERVICE 28..................
Ignition Coil (With Built-in Power Transistor)
Check 28...................................
Resistive Cord Check 28.....................
Spark Plug Check, Cleaning and Replacement 29
Camshaft Position Sensor Check 29...........
Crank Angle Sensor Check 29................
Detonation Sensor Check 29..................
Waveform Check Using An Analyzer 30........
IGNITION COIL 34.........................
CAMSHAFT POSITION SENSOR 35.........
CRANK ANGLE SENSOR 35................
DETONATION SENSOR 37.................

ENGINE ELECTRICAL -Charging System16-2
CHARGING SYSTEM
GENERAL INFORMATION
The charging system uses the alternator output
to keep the battery charged at a constant level
under various electrical loads.
OPERATION
Rotation of the excited field coil generates AC voltage in
the stator.
This alternating current is rectified through diodes to DC
voltage having a waveform shown in the illustration at left.
The average output voltage fluctuates slightly with the
alternator load condition.
When the ignition switch is turned on, current flows
in the field coil and initial excitation of the field
coil occurs.
When the stator coil begins to generate power after
the engine is started, the field coil is excited by
the output current of the stator coil.
The alternator output voltage rises as the field
current increases and it falls as the field current
decreases. When the battery voltage (alternator
S terminal voltage) reaches a regulated voltageof approximately 14.4 V, the field current is cut
off. When the battery voltage drops below the
regulated voltage, the voltage regulator regulates
the output voltage to a constant level by controlling
the field current.
In addition, when the field current is constant, the
alternator output voltage rises as the engine speed
increases.
SYSTEM DIAGRAM
Stator coil
Field coil
Voltage
regulatorEngine-ECU
Charging
warning lampIgnition
switchBattery B
G
L
FRS
Voltage
Time
Approximately
14.4 V

ENGINE ELECTRICAL -Charging System16-3
ALTERNATOR SPECIFICATIONS
ItemsSpecifications
TypeBattery voltage sensing
Rated output V/A12/90
Voltage regulatorElectronic built-in type
SERVICE SPECIFICATIONS
ItemsStandard valueLimit
Alternator output line voltage drop (at 30 A) V-max. 0.3
Regulated voltage ambient
tempatvoltageregulatorV
-20_C14.2 - 15.4-
temp. atvoltage regulatorV
20_C13.9 - 14.9-
60_C13.4 - 14.6-
80_C13.1 - 14.5-
Output current-70 % of normal output current
Rotor coil resistanceΩApprox. 3 - 5-
Protrusion length of brush mm-2
SPECIAL TOOL
ToolNumberNameUse
MB991519Alternator test
harnessChecking the alternator (S terminal voltage)