1999 MITSUBISHI LANCER EVOLUTION VI Workshop Manual

ENGINE – Alternator11-80
DISASSEMBLY SERVICE POINTS
AFRONT BRACKET ASSEMBLY REMOVAL
Insert a flat tip screwdrivers or the like in the clearance between
the front bracket assembly and stator core, to pry open and
separate the stator and front bracket.
Caution
Do not insert the screwdriver too far, or the stator coil
gets damaged.
BALTERNATOR PULLEY REMOVAL
Face pulley side upward, fix the rotor with a work bench
and remove the pulley.
Caution
Use care not to damage the rotor.
CSTATOR / REGULATOR ASSEMBLY REMOVAL
(1) Unsolder the stator with a soldering iron (180 to 250
W). Complete this work within four seconds not to transfer
heat to the diode.
(2) When removing rectifier from the regulator assembly,
remove the soldered sections to rectifier.
Caution
1. Use care to make sure that the heat of the soldering
iron is not transmitted to the diodes for a long
period.
2. Use care that no undue force is exerted to the
lead wires of the diodes.
REASSEMBLY SERVICE POINTS
AREGULATOR ASSEMBLY INSTALLATION
After installing the regulator assembly, insert a wire into the
hole provided on the rear bracket while pressing in the brush
to fix the brush.
NOTE
The brush is fixed when a wire is inserted, making rotor
installation easier.
Soldered
Rear bracket
Brush
WireWire

ENGINE – Alternator11-81
BROTOR INSTALLATION
After installing the rotor, remove the wire used to fix the brush.
INSPECTION
ROTOR CHECK
(1) Check the continuity between the rotor coil slip rings,
and replace the rotor if the resistance value is not at
the standard value.
Standard value: 3 – 5 Ω
(2) Check the continuity between the slip ring and core, and
if there is continuity, replace the rotor.
STATOR CHECK
(1) Check the continuity between the coil leads, and if there
is continuity, replace the stator.
(2) Check the continuity between the coil and core, and if
there is continuity, replace the stator.
Wire

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.