MITSUBISHI LANCER EVOLUTION 2007 Service Repair Manual

ENGINE ELECTRICAL -Starting System16-19
5. If pinion gap is out of specification, adjust by adding or
removing gaskets between magnetic switch and front
bracket.
MAGNETIC SWITCH PULL-IN TEST
1. Disconnect field coil wire from M-terminal of magnetic
switch.
2. Connect a 12 V battery between S-terminal and
M-terminal.
Caution
This test must be performed quickly (in less than
10 seconds) to prevent coil from burning.
3. If pinion moves out, then pull-in coil is good. If it doesn’t,
replace magnetic switch.
MAGNETIC SWITCH HOLD-IN TEST
1. Disconnect field coil wire from M-terminal of magnetic
switch.
2. Connect a 12 V battery between S-terminal and body.
Caution
This test must be performed quickly (in less than 10
seconds) to prevent coil from burning.
3. Manually pull out the pinion as far as the pinion stopper
position.
4. If pinion remains out, everything is in order. If pinion moves
in, hold-in circuit is open. Replace magnetic switch.
FREE RUNNING TEST
1. Place starter motor in a vise equipped with soft jaws
and connect a fully-charged 12 V battery to starter motor
as follows:
2. Connect a test ammeter (100-ampere scale) and carbon
pile rheostat in series with battery positive post and starter
motor terminal.
3. Connect a voltmeter (15 V scale) across starter motor.
4. Rotate carbon pile to full-resistance position.
5. Connect battery cable from battery negative post to starter
motor body.
6. Adjust the rheostat until the battery voltage shown by
the voltmeter is 11 V Reduction.
7. Confirm that the maximum amperage is within the
specifications and that the starter motor turns smoothly
and freely.
Current:
max. 90 A
Field coil wire S
M
Battery
B
Field coil wire S
Battery
M S
B
Starter
motorAmmeter
Battery
Voltmeter
Carbon-pile rheostat
A
V

ENGINE ELECTRICAL -Starting System16-20
MAGNETIC SWITCH RETURN TEST
1. Disconnect field coil wire from M-terminal of magnetic
switch.
2. Connect a 12 V battery between M-terminal and body.
Caution
This test must be performed quickly (in less than
10 seconds) to prevent coil from burning.
3. Pull pinion out and release. If pinion quickly returns to
its original position, everything is in order. If it doesn’t,
replace magnetic switch.
Caution
Be careful not to get your fingers caught when pulling
out the pinion.
Field coil wire M
Battery

ENGINE ELECTRICAL -Starting System16-21
DISASSEMBLY AND REASSEMBLY
1 1713
1512
4 3
211
6 1614
1098
7 5
182021
19
22
Disassembly steps
1. Cover
2. Screw
AA"3. Magnetic switch
4. Screw
5. Through
6. Rear bracket
7. Brush holder
8. Rear bearing
AB"9. Armature
10. Yoke assembly
AB"11. Ball12. Packing A
13. Packing B
14. Plate
15. Planetary gear
16. Lever
AC""AA17. Snap ring
AC""AA18. Stop ring
19. Overrunning clutch
20. Internal gear
21. Planetary gear holder
22. Front bracket

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

ENGINE ELECTRICAL -Starting System16-25
ARMATURE COIL OPEN-CIRCUIT INSPECTION
Check the continuity between segments. If there is continuity,
the coil is in order.
MAGNETIC SWITCH
COIL DISCONNECTION TEST
DConfirm that there is continuity between the “M” terminal
and body A.
DIf there is no continuity, replace the magnetic switch.
CONTACT CONTACTING STATE CHECK
DConfirm that there is no continuity between the “B” terminal
and “M” terminal.
DIf there is continuity, replace the magnetic switch.
CONTACT CONTACTING STATE CHECK
DPress the end of the magnetic switch in with force, and
close the internal contact. Confirm that there is continuity
between the “B” terminal and “M” terminal in this state.
DIf there is no continuity, replace the magnetic switch.
“M” terminal A
“M” terminal “B” terminal
“M” terminal “B” terminal

ENGINE ELECTRICAL -Ignition System16-26
IGNITION SYSTEM
GENERAL INFORMATION
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
primary side of ignition coil A generates a high
voltage in the secondary side of ignition coil A.
The high voltage 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 turns the two power transistors
inside the ignition coils alternately on and off. Thiscauses the primary currents in the ignition coils
to be alternately interrupted and allowed to flow
to fire the cylinders in the order 1-3-4-2.
The Engine-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 conditions. 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
altitudes, the ignition timing is slightly advanced
to provide optimum performance.
When the automatic transmission shifts gears, the
ignition timing is also retarded in order to reduce
output torque, thereby alleviating shifting shocks.
SYSTEM DIAGRAM
Barometric pressure sensor
Intake air temperature sensor
Engine coolant temperature sensor
Camshaft position sensor
Crank angle sensor
Ignition switch - ST
Vehicle speed signalEngine-ECU
Ignition coil A
Ignition coil B Ignition switch
Spark plugBattery
To tachometerCylinder No. Air flow sensor
1 4
23
Detonation sensor

ENGINE ELECTRICAL -Ignition System16-27
IGNITION COIL SPECIFICATIONS
ItemsSpecifications
TypeMolded 2-coil
SPARK PLUG SPECIFICATIONS
ItemsSpecifications
NGKIGR7A-G
DENSOVW22PR-DA7
SERVICE SPECIFICATIONS
IGNITION COIL
ItemsStandard value
Secondary coil resistance kΩ8.5 - 11.5
SPARK PLUG
ItemsStandard valueLimit
Spark plug gap mm0.6 - 0.70.75
RESISTIVE CORD
ItemsLimit
Resistance kΩmax. 22
SPECIAL TOOL
ToolNumberNameUse
MD998773Detonation sensor
wrenchDetonation sensor removal and installation

ENGINE ELECTRICAL -Ignition System16-28
ON-VEHICLE SERVICE
IGNITION COIL (WITH BUILT-IN POWER
TRANSISTOR) CHECK
Check by the following procedure, and replace if there is
a malfunction.
SECONDARY COIL RESISTANCE CHECK
Measure the resistance between the high-voltage terminals
of the ignition coil.
Standard value: 8.5 - 11.5 kΩ
PRIMARY COIL AND POWER TRANSISTOR
CONTINUITY CHECK
NOTE
1. An analogue-type circuit tester should be used.
2. Connect the negative ( - ) prove of the circuit tester to
terminal 1.
Caution
This test must be performed quickly (in less than 10
seconds) to prevent coil from burning and power
transistor from breakage.
1.5V power across 2 - 3Continuity across 1 - 2
When energizedYe s
When not energizedNo
RESISTIVE CORD CHECK
Measure the resistance of the all spark plug cables.
1. Check cap and coating for cracks.
2. Measure resistance.
Limit: Max. 22 kΩ