2006 MITSUBISHI LANCER Workshop Manual

EXHAUST MANIFOLD
INTAKE AND EXHAUST15-7
INSPECTION
M1151003100616
Check the following points; replace the part if a prob-
lem is found.
Inlet Manifold Check
1. Check for damage or cracking of any part.
2. Clogging of the negative pressure (vacuum) outlet port, or clogging of the exhaust gas recirculation
passages.
3. Using a straight edge and feeler gauge, check for distortion of the cylinder head installation surface.
Standard value: 0.15 mm or less
Limit: 0.20 mm
EXHAUST MANIFOLD
REMOVAL AND INSTALLATION <4G1>
M1151003300568
AC30366250 ± 10 N·m
24 ± 4 N·m
35 ± 6 N·m 17 ± 2 N·m
30 ± 2 N·m
N
3
7 12
4
N
6
8
44 ± 5 N·m
AB
9
5N
30 ± 2 N·m
30 ± 2 N·m
30 ± 2 N·m
(Engine oil)
8.Battery wirin g ha rne s s clamp
9.Inlet manifold st ay
10.Inlet manifold
11.Inlet manifold gask et
12.Emission vacuu m hose & pipe and
emis
sion s o lenoid valve assembly
13.EGR v a lve
14.EGR v a lve gasket
Remo va l st ep s ( C o n t in u e d)

Removal steps
1.Front exhaust pipe connection
2.Exhaust pipe gasket
<>>>A<<3.Engine control oxygen sensor (front)
4.Engine oil level gauge and guide
assembly
5.Engine oil filler O-ring
6.Exhaust manifold cover
7.Exhaust manifold bracket
8.Exhaust manifold
9.Exhaust manifold gasket
EXHAUST MANIFOLD
INTAKE AND EXHAUST15-8
REMOVAL SERVICE POINT
<> ENGINE CONTROL OXYGEN SEN-
SOR (FRONT) REMOVAL
AC212566AC
MD998770
Engine control
oxygen sensor
(front)
Use spe c ia l tool oxyg en sen s or wrench (MD9987 70)
to remove t
he eng ine contro l oxygen sen s or (fro nt).
INSTALLA T ION SER VICE POINT
>>A<< ENGINE CONT ROL OXYGEN SEN-
SOR (FRONT) INSTALLA TION
AC212566AC
MD998770
Engine control
oxygen sensor
(front)
Use spe c ia l tool oxyg en sen s or wrench (MD9987 70)
to inst
all the eng ine contro l oxyge n sen s or (f ront).

EXHAUST MANIFOLD
INTAKE AND EXHAUST15-9
REMOVAL AND INSTALLATION <4G6>
M1151003300579
Pre-removal and Post-installation Operation
Under cover Removal and Installation
AC30368050 ± 10 N·m
44 ± 5 N·m
35 ± 6 N·m14 ± 1 N·m
14 ± 1 N·m
49 ± 5 N·m 29 ± 3 N·m
29 ± 3 N·m
N
3
4
1 2
5
N
8 944 ± 5 N·m
AB
1049 ± 5 N·m
6
7
9.0 ± 2.0 N·m 49 ± 9 N·m
Removal steps
1.Front exhaust pipe connection
2.Exhaust pipe gasket
<>>>A<<3.Engine control oxygen sensor (front)
4.Exhaust manifold cover
5.Exhaust manifold bracket
6.Starter cover
7.Starter cover bracket
8.Engine hanger
9.Exhaust manifold
10.Exhaust manifold gasket
Removal steps (Continued)

EXHAUST PIPE AND MAIN MUFFLER
INTAKE AND EXHAUST15-10
REMOVAL SERVICE POINT
<> ENGINE CONTROL OXYGEN SEN-
SOR (FRONT) REMOVAL
AC212566AC
MD998770
Engine control
oxygen sensor
(front)
Use spe c ia l tool oxyg en sen s or wrench (MD9987 70)
to remove t
he eng ine contro l oxygen sen s or (fro nt).
INSTALLA T ION SER VICE POINT
>>A<< ENGINE CONT ROL OXYGEN SEN-
SOR (FRONT) INSTALLA TION
AC212566AC
MD998770
Engine control
oxygen sensor
(front)
Use spe c ia l tool oxyg en sen s or wrench (MD9987 70)
to inst
all the eng ine contro l oxyge n sen s or (f ront).
INSPECTIONM1151 0034 0054 3
Chec k the fo llowing point s; rep l ace the p a rt if a p r ob-
lem is found.
Exhaust Manifold Check
1.Check f o r damage o r cracking of a n y p a rt.
2.Using a straight e dge an d a fee l er ga uge, check
fo r distortio n of th e cylin der he ad in st allation
surface.
St a ndard val ue: 0.15 mm or les s
Limit: 0.20 mm
EXHAUST PIPE AND MAI N MUFFLER
REMOVA L AND INST ALLA TION
M1151 0087 0096 9
AC303694AC
1
3
50 ± 10 N·m
2
7
N
N
45
8 4
N9
10
59 ± 10 N·m
45 ± 5 N·m
13 ± 2 N·m
45 ± 5 N·m
13 ± 2 N·m
10
<4G1>

AC303695AC
1
3
50 ± 10 N·m
2
7
N
N
45
8 4
N9
10
59 ± 10 N·m
45 ± 5 N·m
13 ± 2 N·m
45 ± 5 N·m
13 ± 2 N·m
10
<4G6-M/T>
AC504798AB
<4G6-A/T> 1
2
3N
4
7N8
N9
10
13 ± 2 N·m
13 ± 2 N·m
45 ± 5 N·m
59 ± 10 N·m
6N
10
4
50 ± 10 N·m
13 ± 2 N·m
13 ± 2 N·m
50 ± 10 N·m
Exhaust main muffler removal
steps

1.Exhaust main muffler
3.Exhaust pipe gasket
4.Exhaust muffler hanger
Centre exhaust pipe removal
steps

2.Centre exhaust pipe
3.Exhaust pipe gasket
6.Exhaust pipe gasket <4G6-A/T>
8.Exhaust pipe gasket <4G1,
4G6-M/T>
Front exhaust pipe removal
steps

<>>>A<<5.Engine control oxygen sensor
(rear) <4G1, 4G6-M/T>
7.Front exhaust pipe
8.Exhaust pipe gasket
9.Exhaust pipe gasket
10.Exhaust muffler hanger
EX HAUS T PIPE AND MAIN MU FFLER
INTAKE AN D EXHAU ST15-11

EXHAUST PIPE AND MAIN MUFFLER
INTAKE AND EXHAUST15-12
REMOVAL SERVICE POINT
<> ENGINE CONTROL OXYGEN SEN-
SOR (REAR) REMOVAL
AC212566AD
MD998770
Engine control
oxygen sensor
(rear)
Use spe c ia l tool oxyg en sen s or wrench (MD9987 70)
to remove t
he eng ine contro l oxygen sen s or (re ar).
INSTALLA T ION SER VICE POINT
>>A<< ENGINE CONT ROL OXYGEN SEN-
SOR (REAR) INSTALLA TION
AC212566AD
MD998770
Engine control
oxygen sensor
(rear)
Use spe c ia l tool oxyg en sen s or wrench (MD9987 70)
to inst
all the eng ine contro l oxyge n sen s or (re ar).

16-1
GROUP 16
ENGINE
ELECTRICAL
CONTENTS
CHARGING SYSTEM . . . . . . . .16-2
GENERAL INFORMATION . . . . . .16-2
SERVICE SPECIFICATIONS. . . . .16-3
SPECIAL TOOL . . . . . . . . . . . . . . .16-3
ON-VEHICLE SERVICE. . . . . . . . .16-3
ALTERNATOR OUTPUT LINE VOLTAGE
DROP TEST . . . . . . . . . . . . . . . . . . . . . 16-3
OUTPUT CURRENT TEST . . . . . . . . . . 16-5
REGULATED VOLTAGE TEST . . . . . . . 16-7
WAVEFORM CHECK USING AN
OSCILLOSCOPE . . . . . . . . . . . . . . . . . . 16-9
ALTERNATOR ASSEMB LY . . . . .16-12
REMOVAL AND INSTALLATION
<4G1> . . . . . . . . . . . . . . . . . . . . . . . . . . 16-12
REMOVAL AND INSTALLATION
<4G6> . . . . . . . . . . . . . . . . . . . . . . . . . . 16-13
DISASSEMBLY AND REASSEMBLY . . 16-15
INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-17
STARTING SYSTEM . . . . . . . . .16-19
GENERAL INFORMATION . . . . . .16-19
SERVICE SPECIFICATIONS. . . . .16-20
STARTER MOTOR ASSEMBLY . .16-21
REMOVAL AND INSTALLATION
<4G1> . . . . . . . . . . . . . . . . . . . . . . . . . . 16-21
REMOVAL AND INSTALLATION
<4G6> . . . . . . . . . . . . . . . . . . . . . . . . . . 16-22
STARTER MOTOR ASSEMBLY
INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-23
DISASSEMBLY AND REASSEMBLY . . 16-26
INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-27
IGNITION SYSTEM . . . . . . . . . 16-30
GENERAL INFORMATION . . . . . .16-30
SERVICE SPECIFICATIONS . . . . .16-31
SPECIAL TOOL . . . . . . . . . . . . . . .16-31
ON-VEHICLE SERVICE . . . . . . . . .16-32
IGNITION COIL (WITH BUILT-IN
POWER TRANSISTOR) CHECK . . . . . . 16-32
RESISTIVE CORD CHECK . . . . . . . . . . 16-32
SPARK PLUG CHECK AND CLEANING
<4G1>. . . . . . . . . . . . . . . . . . . . . . . . . . . 16-32
SPARK PLUG CHECK AND CLEANING
<4G6>. . . . . . . . . . . . . . . . . . . . . . . . . . . 16-33
CAMSHAFT POSITION SENSOR
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . 16-33
CRANK ANGLE SENSOR CHECK . . . . 16-33
DETONATION SENSOR CHECK . . . . . 16-33
IGNITION SECONDARY VOLTAGE
WAVEFORM CHECK USING AN
OSCILLOSCOPE . . . . . . . . . . . . . . . . . . 16-33
IGNITION COIL RELAY CHECK . . . . . . 16-37
IGNITION COIL . . . . . . . . . . . . . . . .16-38
REMOVAL AND INSTALLATION
<4G1>. . . . . . . . . . . . . . . . . . . . . . . . . . . 16-38
REMOVAL AND INSTALLATION
<4G6>. . . . . . . . . . . . . . . . . . . . . . . . . . . 16-39
CAMSHAFT POSITION SENSOR .16-40
REMOVAL AND INSTALLATION . . . . . . 16-40
CRANKSHAFT POSITION SENSOR16-41
REMOVAL AND INSTALLATION
<4G1>. . . . . . . . . . . . . . . . . . . . . . . . . . . 16-41
REMOVAL AND INSTALLATION
<4G6>. . . . . . . . . . . . . . . . . . . . . . . . . . . 16-42
DETONATION SENSOR . . . . . . . .16-43
REMOVAL AND INSTALLATION . . . . . . 16-43

CHARGING SYSTEM
ENGINE ELECTRICAL16-2
CHARGING SYSTEM
GENERAL INFORMATIONM1161000100522
The charging system uses the alternator output to
keep the battery charged at a constant level under
various electrical loads.
OPERATION
AKX00183
VoltageTime
Approximately
14.4 V
AC
Rota tion of the excited fi eld coil gene rates AC volt-
age in the sta t or .
This alternatin g cur r ent is rectified throu gh diodes to
DC volt
age h a ving a waveform sh own in t he illustra
-
tion.
The average outpu t volt a ge flu c tua t es slightly with
the alternato
r load con d ition.
When the ign i tion switch is t u rned on, current flows in
the field coil and initial e
x cit a tion of the field coil
occurs.
When the st ator coil beg ins to gen erate p o wer af ter
the eng
ine is st a r ted, th e fie l d coil is excited by th e
output
curren t of th e st ator coil.
The alternator outpu t volt a ge rises as th e fie l d cur-
rent increa ses and it falls a s the field cu rrent
decre
ases. Whe n the b a ttery volt a ge (alternato r "S"
terminal volt
ag e) reaches a regulated volt ag e of
approximately 14.4
V , the field current is cut o f f.
When th
e batte ry volt age drop s be low the regulated
volt
ag e, the volt ag e regulator re gulat es th e outp u t
volt
ag e to a const ant level by contro lling the field cur
-
rent.
In addition, when th e fie l d current is const a n t, the
altern
ator ou tput volt age rise s as the e ngine spe ed
increase
s .
SYSTEM DIAGRAM
AK400308
Alternator
B
Stator coil
Engine-ECU or
Engine-A/T-ECU
G
SL
FR
<4G1>
Voltage regulator Charge warning lightIgnition switch
Battery
Field coil
+
–
AB
AL TERNA T O R SPECIFICA T IONS
Item4G14G6
Ty p eBattery voltage sensing
Rated output V/A12/8012/110
Voltage regulatorElectronic built-in type