1999 MITSUBISHI LANCER EVOLUTION VI engine

ENGINE – Alternator11-82
RECTIFIERS CHECK
(1) Inspect the (+) heat sink by checking the continuity
between the (+) heat sink and stator coil lead wire
connection terminal using a tester probe.
If there is a continuity at both, the diode is short circuited,
so replace the rectifier.
(2) Inspect the (–) heat sink by checking the continuity
between the (–) heat sink and stator coil lead wire
connection terminal using a tester probe.
If there is a continuity at both, the diode is short circuited,
so replace the rectifier.
(3) Check the diode trio by connecting an ohmmeter to both
ends of each diode and check the continuity of the three
diodes.
If there is a continuity at both ends, or if there is no
continuity, the diode is damaged so replace the recitifier.
BRUSH CHECK
(1) Measure the length of the brush protrusion shown in the
illustration, and replace the brush if the measured value
is below the limit value.
Limit: 2 mm or less
(2) The brush can be removed if the solder of the brush
lead wire is removed.
(3) When installing a new brush, insert the brush into the
holder as shown in the illustration, and then solder the
lead wires.
Protrusion
length
Soldered

ENGINE – Starter Motor11-83
STARTER MOTOR
DISASSEMBLY AND REASSEMBLY
1 23
4 5
6
789
10 1112 13 14
15
16 17
18 19
202122
23
Disassembly steps
1. Cover
2. Screw
A3. Magnetic switch
4. Screw
5. Through
6. Rear bracket
7. Brush holder
8. Brush
9. Rear bearing
B10. Armature
11. Yoke assembly
B12. Ball13. Packing A
14. Packing B
15. Plate
16. Planetary gear
17. Lever
CA18. Snap ring
CA19. Stop ring
20. Overrunning clutch
21. Internal gear
22. Planetary gear holder
23. Front bracket

ENGINE – Starter Motor11-84
DISASSEMBLY SERVICE POINTS
AMAGNETIC SWITCH REMOVAL
Disconnect field coil wire from “M” terminal of magnetic switch.
BARMATURE / BALL REMOVAL
Caution
When removing the armature, take care not to lose the
ball (which is used as a bearing) in the armature end.
CSNAP 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.
Magnetic
switch“S” terminal
“B” terminal
Field coil wire “M” terminal
Stop ringSocket
Pinion gear
Overrunning
clutch
Armature
Snap ring
Pinion gear
Overrunning
clutchSnap ring pliers
Armature

ENGINE – Starter Motor11-85
REASSEMBLY SERVICE POINTS
ASTOP RING / SNAP RING INSTALLATION
Using a suitable pulling tool, pull overrunnig 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: 32.0 mm
Limit: 31.4 mm
(3) Check the undercut depth between segments.
Standard value: 0.5 mm
BRUSH HOLDER CHECK
Check the continuity between brush holder plate and brush
holder.
If there is no continuity, the brush holder is in order.
Stop ringOverrunning
clutchStop ring
Snap ring
Undercut
Segment
Mica
Brush holder

ENGINE – Starter Motor11-86
OVERRUNING 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 overrunnig 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 AND SPRING REPLACEMENT
(1) Brushes that are worn beyond wear limit line, or oil-soaked,
should be replaced.
(2) When replacing ground brush, slide the brush from brush
holder by prying retaining spring back.
ARMATURE TEST
ARMATURE COIL SHORT-CIRCUIT TEST
(1) Place armature in a growler.
(2) 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
Wear limit line
Growler

ENGINE – Starter Motor11-87
ARMATURE COIL OPEN-CIRCUIT INSPECTION
Check the continuity between segments. If there is continuity,
the coil is in order.

13-1
FUEL
CONTENTS
MULTIPOINT INJECTION (MPI) 2. . . . . . .
GENERAL 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outline of Change 2. . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE SPECIFICATIONS 4. . . . . . . . . . . . . .
SEALANT 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 5. . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 6. . . . . . . . . . . . . . . . . . . . ON-VEHICLE SERVICE 68. . . . . . . . . . . . . . . .
Fuel Pump Resistor Check 68. . . . . . . . . . . . . . . .
Fuel Pump Relay No.2
Continuity Check 68. . . . . . . . . . . . . . . . . . . . . . . . .
Engine Control Relay and Fuel Pump Relay
Continuity Check 68. . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SUPPLY 69. . . . . . . . . . . . . . . . . . . . .
GENERAL 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outline of Change 69. . . . . . . . . . . . . . . . . . . . . . . .
FUEL TANK 69. . . . . . . . . . . . . . . . . . . . . . . . . . .

MPI – General13-3
MPI System Diagram
1 Injector
2 ISC servo
3 Fuel pressure control valve
4 Waste gate solenoid valve
5 Secondary air control solenoid valve

Control relay

Fuel pump relay

A/C relay

Ignition coil

Exhaust temperature warning lamp

Engine warning lamp

Diagnosis output

Alternator G terminal

Fan motor relay

Tachometer

Fuel pump relay No.2 1 Oxygen sensor
2 Air flow sensor
3 Intake air temperature sensor
4 Throttle position sensor
5 Idle switch
6 Camshaft position sensor
7 Crank angle sensor
8 Barometric pressure sensor
9 High temperature sensor
10 Engine coolant temperature sensor
11 Detonation sensor

Power supply voltage

Ignition switch-IG

Ignition switch-ST

Vehicle speed sensor

A/C switch

Power steering fluid pressure switch

Alternator FR signalEngine ECU
1 Oxygen sensor
2 Air flow sensor3
Intake air tem-
perature sensor
4,
5
6 Camshaft position
sensor
7 Crank angle sensor 8 Barometric
pressure sensor
9 High temperature
sensor 10 Coolant temperature sensor
11 Detonation sensor1 Injector 2 ISC servo
3 Fuel pressure
control valve
4 Waste gate
solenoid valve 5 Secondary air
control solenoid
valveCanister
Check valveFrom
fuel
tank
Throttle position
sensor (with a
built-in
idle
switch)
Secondary
air valve
AirTo fuel
tankFuel
pressure
regulatorFrom
fuel
pump
Waste gate
actuator
Catalytic converter