2005 MITSUBISHI LANCER service

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Page 76 of 788

MITSUBISHI LANCER 2005 Workshop Manual CHARGING SYSTEM
ENGINE ELECTRICAL16-12
ALTERNATOR ASSEMBLY
REMOVAL AND INSTALLATION <4G1>M1161001400548
REMOVAL SERVICE POINT
<<A>> ALTERNATOR ASSEMBLY
REMOVAL
Remove the alternator assembly from abo

Page 77 of 788

MITSUBISHI LANCER 2005 Workshop Manual CHARGING SYSTEM
ENGINE ELECTRICAL16-13
REMOVAL AND INSTALLATION <4G6>M1161001400559
Pre-removal Operation
•Under Cover Removal
•Strut Tower Bar Removal (Refer to GROUP 42 P.42-9).
•Drive Belt Re

Page 78 of 788

MITSUBISHI LANCER 2005 Workshop Manual CHARGING SYSTEM
ENGINE ELECTRICAL16-14
REMOVAL SERVICE POINT
<<A>> SHIFT CABLE AND SHIFT CABLE
BRACKET ASSEMBLY REMOVAL
Remove the shift cable bracket installation bolt with
the shift cable installe

Page 80 of 788
CHARGING SYSTEM
ENGINE ELECTRICAL16-16
DISASSEMBLY SERVICE POINTS
<>FRONT BRACKET ASSEMBLY
REMOVAL
CAUTION
Do not insert the screwdriver blades too deep.
Doing so could damage the stator coil.
Insert the blades of screwdrivers between the front
bracket assembly and stator core, and pry and
separate them with the screwdrivers.
<>ALTERNATOR PULLEY REMOVAL
CAUTION
Perform operation carefully not to damage the
rotor.
Clamp the rotor in a vise with the pulley facing up to
remove the pulley.
<>STATOR / REGULATOR ASSEMBLY
REMOVAL
CAUTION
•Use a 180 − 250 W soldering iron, and finish
unsoldering within four seconds. Diodes will
be damaged by heat if unsoldering time is too
long.
•Avoid applying undue force to the diode
leads.
1. Unsolder the stator leads from the main diode of
the rectifier assembly when the stator is removed.
2. When removing the rectifier assembly from the
regulator assembly, undo the soldered points on
the rectifier assembly.
REASSEMBLY SERVICE POINTS
>>A< INSTALLATION
After installing the regulator assembly, insert a piece
of wire through the hole in the rear bracket while
pressing the brush to keep the brush against
movement.
NOTE: Holding the brush with the wire facilities
installation of the rotor.
AK202718
AK202714
AK202778
Solder
Solder Rectifier
assembly
AB
AK202779
Wire
AB
AK202830
Rear bracket
Brush
Wire
AB

Page 84 of 788
STARTING SYSTEM
ENGINE ELECTRICAL16-20
STARTER MOTOR SPECIFICATIONS
SERVICE SPECIFICATIONS
M1162000300068
Item 4G1 4G6
Type Reduction drive with planetary
gearReduction drive with planetary gear
Rated output kW/V 1.2/12 1.4/12
Number of pinion teeth 8 8
Item Standard value Limit
Pinion gap mm 0.5 − 2.0
−
Commutator run-out mm
−0.05
Commutator diameter mm 29.4 28.8
Undercut depth mm 0.5 0.2

Page 85 of 788
STARTING SYSTEM
ENGINE ELECTRICAL16-21
STARTER MOTOR ASSEMBLY
REMOVAL AND INSTALLATION <4G1>M1162001000628
REMOVAL SERVICE POINT
<> SHIFT CABLE AND SHIFT CABLE
BRACKET ASSEMBLY REMOVAL
Remove the shift cable bracket installation bolt with
the shift cable installed on the shift cable bracket,
and remove the shift cable and shift cable bracket
assembly from the transmission.
<> SHIFT CABLE CONNECTION
REMOVAL
Disengage the transmission, and remove the shift
cable assembly from the transmission.
<> STARTER ASSEMBLY REMOVAL
Remove the starter assembly from above the
vehicle.
Pre-removal and Post-installation Operation
•Air Cleaner Assembly Removal and Installation (Refer to
GROUP 15 P.15-3).
•Battery and Battery Tray Removal and Installation
AC303962AB
1
1 2
3
56
7
4
30 ± 3 N·m18 ± 3 N·m
12 ± 2 N·m

Removal steps
1. Shift cable connection
<>2. shift cable and shift cable bracket
assembly
<>3. Shift cable connection 4. Starter connector and terminal
5. Harness bracket
6. Harness bracket <>7. Starter assemblyRemoval steps (Continued)

Page 86 of 788
STARTING SYSTEM
ENGINE ELECTRICAL16-22
REMOVAL AND INSTALLATION <4G6>M1162001000617
REMOVAL SERVICE POINT
<> STARTER ASSEMBLY REMOVAL
Remove the starter assembly from above the
vehicle.
Pre-removal and Post-installation Operation
•Air Cleaner Assembly Removal and Installation (Refer to
GROUP 15 P.15-3).
•Under Cover Removal and Installation
AC304005
521
6
49 ± 9 N·m 18 ± 3 N·m9.0 ± 2.0 N·m
30 ± 3 N·m
AB
4
3
Removal steps
1. Starter cover
2. Starter connector and terminal
3. Clutch release cylinder connecting
bolts4. Clutch hose clamp
<>5. Starter assembly
6. Starter cover bracketRemoval steps (Continued)

Page 91 of 788
STARTING SYSTEM
ENGINE ELECTRICAL16-27
DISASSEMBLY SERVICE POINTS
<> MAGNETIC SWITCH REMOVAL
CAUTION
Do not clamp the yoke assembly with a vise.
Disconnect the lead from the M terminal of the
magnetic switch.
<> SNAP RING/STOP RING REMOVAL
1. Apply a long socket wrench of an appropriate size
to the stop ring and strike the wrench to drive out
the stop ring toward the pinion gear side.
2. Remove the snap ring with snap ring pliers, then
remove the stop ring and overrunning clutch.
STARTER MOTOR PARTS CLEANING
Never clean in a solvent such starter motor parts
as the magnetic switch, brush holder, and
armature. If they are soaked in a solvent, their
insulation could be impaired. When these parts
require cleaning, wipe off contamination with
cloth.
1. Never soak the drive unit in a solvent. If it is
washed in a solvent, the grease having been
packed in the overrunning clutch at the factory will
be washed out. Wipe the drive unit with cloth if it
requires cleaning.
REASSEMBLY SERVICE POINTS
>>A<< STOP RING/SNAP RING
INSTALLATION
Use a suitable puller to pull the stop ring until it gets
over the snap ring.
INSPECTION M1162001300157
COMMUTATOR
1. Support the armature with a pair of V block and
turn it to measure the runout of the surface not
rubbed by the brushes using a dial gauge.
Standard value: 0.05 mm or less
Limit: 0.1 mm
AK201882
B terminal
M terminal S terminal
AC
AK100883AC
Socket wrench
Stop ring
Pinion Gear
Overrunning
clutch
AK202791
Snap ring
pliersSnap ring
Pinion gear
Overrunning
clutch
AB
AK202911
Overrunning
clutchStop ring
Snap ring Stop ring
AB
AK202712

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