2007 MITSUBISHI LANCER EVOLUTION charging

INTAKE AND EXHAUST -Service Specifications/Special Tool/On-vehicle Service15-3
SERVICE SPECIFICATIONS
ItemStandard valueLimit
Turbocharger supercharging pressure (waste gate solenoid
valve not operating) kPa59 - 84-
Initial activation pressure of waste gate actuator (at the stroke
of approximately 1 mm) kPaApproximately 100-
Waste gate solenoid valve coil resistance (at 20_C)Ω29 - 35-
Initial activation pressure of air bypass valve kPaApproximately 53-
Secondary air control solenoid valve coil resistance
(at 20_C)Ω29 - 35-
Manifold distortion of the installation surface mm0.15 or less0.20
SPECIAL TOOL
ToolNumberNameUse
MD998770Oxygen sensor wrenchRemoval and installation of oxygen sensor
ON-VEHICLE SERVICE
TURBOCHARGER SUPERCHARGING
PRESSURE CHECK
Caution
Two persons should be in the vehicle when the test is
conducted; the person in the passenger seat should read
the indications shown by the pressure meter.
1. Disconnect the hose (black) from the turbocharger waste
gate solenoid valve, and connect the pressure gauge
to the hose. Plug the nipple of the solenoid valve from
which the hose (black) has been disconnected.
2. Drive at full-throttle acceleration in second gear and then
measure the supercharging pressure when the engine
speed in about 3,000 r/min.
Standard value: 59 – 84 kPa
3. If the supercharging pressure deviates from the standard
value, check the following items for possible cause.
DMalfunction of the waste gate actuator
DLeakage of supercharging pressure
DMalfunction of the turbocharger
Throttle bodyWaste gate
solenoid valve
Plug

INTAKE AND EXHAUST -On-vehicle Service15-4
4. When the indicated supercharging is more than standard
value, supercharging control may be faulty, therefore
check the followings.
DMalfunction of the waste gate actuator
DMalfunction of waste gate valve
DDisconnection or cracks of the waste gate actuator
rubber hose
SUPERCHARGING PRESSURE CONTROL
SYSTEM CHECK
1. Disconnect the hose (black) from the turbocharger waste
gate solenoid valve and connect a three-way joint between
the hose and the solenoid valve.
2. Connect a hand vacuum pump to the three-way joint.
3. Disconnect the hose from the turbocharger waste gate
actuator control boost nipple and plug the nipple.
4. Applying a negative pressure with the hand vacuum pump,
check tightness both when the hose end is closed and
when it is open.
Engine stateHose endNormal state
Stop (Ignition
it h“ON”
OpenedNegative pressure leaks.p(g
switch: “ON”
position)ClosedNegative pressure is
maintained.
Idling (after
warm-up)Negative pressure leaks.
NOTE
If this check indicates an abnormal condition, the
turbocharger waste gate actuator, turbocharger waste
gate solenoid or hose is broken.
WASTE GATE ACTUATOR CHECK
1. Connect a manual pump (pressure-application type) to
nipple.
2. While gradually applying pressure, check the pressure that
begins to activate (approximately 1 mm stroke) the waste
gate actuator rod.
Standard value: Approximately 100 kPa
Caution
In order to avoid damage to the diaphragm, do not
apply a pressure of 117 kPa or higher.
Waste gate
solenoid valveThrottle body
Waste gate
actuator
Boost hose

16-1
ENGINE
ELECTRICAL
CONTENTS
CHARGING SYSTEM 2................
GENERAL INFORMATION 2................
SERVICE SPECIFICATIONS 3...............
SPECIAL TOOL 3..........................
ON-VEHICLE SERVICE 4...................
Alternator Output Line Voltage Drop Test 4......
Output Current Test 5........................
Regulated Voltage Test 7.....................
Waveform Check Using An Analyzer 8..........
ALTERNATOR 10..........................
STARTING SYSTEM 17................
GENERAL INFORMATION 17...............
SERVICE SPECIFICATIONS 17..............
ON-VEHICLE SERVICE 18..................
STARTER 18..............................
IGNITION SYSTEM 26.................
GENERAL INFORMATION 26...............
SERVICE SPECIFICATIONS 27..............
SPECIAL TOOL 27.........................
ON-VEHICLE SERVICE 28..................
Ignition Coil (With Built-in Power Transistor)
Check 28...................................
Resistive Cord Check 28.....................
Spark Plug Check, Cleaning and Replacement 29
Camshaft Position Sensor Check 29...........
Crank Angle Sensor Check 29................
Detonation Sensor Check 29..................
Waveform Check Using An Analyzer 30........
IGNITION COIL 34.........................
CAMSHAFT POSITION SENSOR 35.........
CRANK ANGLE SENSOR 35................
DETONATION SENSOR 37.................

ENGINE ELECTRICAL -Charging System16-2
CHARGING SYSTEM
GENERAL INFORMATION
The charging system uses the alternator output
to keep the battery charged at a constant level
under various electrical loads.
OPERATION
Rotation of the excited field coil generates AC voltage in
the stator.
This alternating current is rectified through diodes to DC
voltage having a waveform shown in the illustration at left.
The average output voltage fluctuates slightly with the
alternator load condition.
When the ignition switch is turned on, current flows
in the field coil and initial excitation of the field
coil occurs.
When the stator coil begins to generate power after
the engine is started, the field coil is excited by
the output current of the stator coil.
The alternator output voltage rises as the field
current increases and it falls as the field current
decreases. When the battery voltage (alternator
S terminal voltage) reaches a regulated voltageof approximately 14.4 V, the field current is cut
off. When the battery voltage drops below the
regulated voltage, the voltage regulator regulates
the output voltage to a constant level by controlling
the field current.
In addition, when the field current is constant, the
alternator output voltage rises as the engine speed
increases.
SYSTEM DIAGRAM
Stator coil
Field coil
Voltage
regulatorEngine-ECU
Charging
warning lampIgnition
switchBattery B
G
L
FRS
Voltage
Time
Approximately
14.4 V

ENGINE ELECTRICAL -Charging System16-3
ALTERNATOR SPECIFICATIONS
ItemsSpecifications
TypeBattery voltage sensing
Rated output V/A12/90
Voltage regulatorElectronic built-in type
SERVICE SPECIFICATIONS
ItemsStandard valueLimit
Alternator output line voltage drop (at 30 A) V-max. 0.3
Regulated voltage ambient
tempatvoltageregulatorV
-20_C14.2 - 15.4-
temp. atvoltage regulatorV
20_C13.9 - 14.9-
60_C13.4 - 14.6-
80_C13.1 - 14.5-
Output current-70 % of normal output current
Rotor coil resistanceΩApprox. 3 - 5-
Protrusion length of brush mm-2
SPECIAL TOOL
ToolNumberNameUse
MB991519Alternator test
harnessChecking the alternator (S terminal voltage)

ENGINE ELECTRICAL -Charging System16-4
ON-VEHICLE SERVICE
ALTERNATOR OUTPUT LINE VOLTAGE DROP TEST
Alternator
Terminal BVoltmeterAmmeter
Battery
+-
+-
This test determines whether the wiring from the
alternator “B” terminal to the battery (+) terminal
(including the fusible line) is in a good condition
or not.
(1) Always be sure to check the following before
the test.
DAlternator installation
DAlternator drive belt tension
(Refer to GROUP 11 - On-vehicle Service.)
DFusible link
DAbnormal noise from the alternator while
the engine is running
(2) Turn the ignition switch to the “LOCK” (OFF)
position.
(3) Disconnect the negative battery cable.
(4) Disconnect the alternator output wire from the
alternator “B” terminal and connect a DC test
ammeter with a range of 0 - 100 A in seriesbetween the “B” terminal and the disconnected
output wire. (Connect the (+) lead of the
ammeter to the “B” terminal, and then connect
the ( - ) lead of the ammeter to the disconnected
output wire.)
NOTE
An inductive-type ammeter which enables
measurements to be taken without
disconnecting the alternator output wire should
be recommended. Using this equipment will
lessen the possibility of a voltage drop caused
by a loose “B” terminal connection.
(5) Connect a digital-type voltmeter between the
alternator “B” terminal and the battery (+)
terminal. (Connect the (+) lead of the voltmeter
to the “B” terminal and the connect the ( - ) lead
of the voltmeter to the battery (+) cable.)

ENGINE ELECTRICAL -Charging System16-5
(6) Reconnect the negative battery cable.
(7) Connect a tachometer or the MUT-II.
(Refer to GROUP 11 - On-vehicle Service.)
(8) Leave the hood open.
(9) Start the engine.
(10)With the engine running at 2,500 r/min, turn
the headlamps and other lamps on and off
to adjust the alternator load so that the value
displayed on the ammeter is slightly above 30
A.
Adjust the engine speed by gradually
decreasing it until the value displayed on the
ammeter is 30 A. Take a reading of the value
displayed on the voltmeter at this time.
Limit: max. 0.3 V
NOTE
When the alternator output is high and the value
displayed on the ammeter does not decrease
until 30 A, set the value to 40 A. Read the
value displayed on the voltmeter at this time.
When the value range is 40 A, the limit is max.
0.4 V.(11) If the value displayed on the voltmeter is above
the limit value, there is probably a malfunction
in the alternator output wire, so check the wiring
between the alternator “B” terminal and the
battery (+) terminal (including fusible link).
If a terminal is not sufficiently tight or if the
harness has become discolored due to
overheating, repair and then test again.
(12)After the test, run the engine at idle.
(13)Turn off all lamps and the ignition switch.
(14)Remove the tachometer or the MUT-II.
(15)Disconnect the negative battery cable.
(16)Disconnect the ammeter and voltmeter.
(17)Connect the alternator output wire to the
alternator “B” terminal.
(18)Connect the negative battery cable.
OUTPUT CURRENT TEST
Charging warning lampVoltmeter
Ammeter
Ignition switch
Alternator relayLoad
Battery
Engine-ECUAlternatorFR
L
S
G
+ -+-
B

ENGINE ELECTRICAL -Charging System16-6
This test determines whether the alternator output
current is normal.
(1) Before the test, always be sure to check the
following.
DAlternator installation
DBattery (Refer to GROUP 54 - Battery.)
NOTE
The battery should be slightly discharged.
The load needed by a fully-charged battery
is insufficient for an accurate test.
DAlternator drive belt tension
(Refer to GROUP 11 - On-vehicle Service.)
DFusible link
DAbnormal noise from the alternator while
the engine is running.
(2) Turn the ignition switch to the “LOCK” (OFF)
position.
(3) Disconnect the negative battery cable.
(4) Disconnect the alternator output wire from the
alternator “B” terminal. Connect a DC test
ammeter with a range of 0 - 100 A in series
between the “B” terminal and the disconnected
output wire. (Connect the (+) lead of the
ammeter to the “B” terminal. Connect the ( - )
lead of the ammeter to the disconnected output
wire.)
Caution
Never use clips but tighten bolts and nuts
to connect the line. Otherwise loose
connections (e.g. using clips) will lead to
a serious accident because of high current.
NOTE
An inductive-type ammeter which enables
measurements to be taken without
disconnecting the alternator output wire should
be recommended.
(5) Connect a voltmeter with a range of 0 - 20 V
between the alternator “B” terminal and the
earth. (Connect the (+) lead of the voltmeter
to the “B” terminal, and then connect the ( - )
lead of the voltmeter to the earth.)
(6) Connect the negative battery cable.
(7) Connect a tachometer or the MUT-II.
(Refer to GROUP 11 - On-vehicle Service.)
(8) Leave the hood open.
(9) Check that the reading on the voltmeter is equal
to the battery voltage.
NOTE
If the voltage is 0 V, the cause is probably
an open circuit in the wire or fusible link between
the alternator “B” terminal and the battery (+)
terminal.(10)Turn the light switch on to turn on headlamps
and then start the engine.
(11) Immediately after setting the headlamps to high
beam and turning the heater blower switch to
the high revolution position, increase the engine
speed to 2,500 r/min and read the maximum
current output value displayed on the ammeter.
Limit: 70 % of normal current output
NOTE
DFor the nominal current output, refer to the
Alternator Specifications.
DBecause the current from the battery will
soon drop after the engine is started, the
above step should be carried out as quickly
as possible in order to obtain the maximum
current output value.
DThe current output value will depend on
the electrical load and the temperature of
the alternator body.
DIf the electrical load is small while testing,
the specified level of current may not be
output even though the alternator is normal.
In such cases, increase the electrical load
by leaving the headlamps turned on for
some time to discharge the battery or by
using the lighting system in another vehicle,
and then test again.
DThe specified level of current also may not
be output if the temperature of the alternator
body or the ambient temperature is too
high. In such cases, cool the alternator and
then test again.
(12)The reading on the ammeter should be above
the limit value. If the reading is below the limit
value and the alternator output wire is normal,
remove the alternator from the engine and
check the alternator.
(13)Run the engine at idle after the test.
(14)Turn the ignition switch to the “LOCK” (OFF)
position.
(15)Remove the tachometer or the MUT-II.
(16)Disconnect the negative battery cable.
(17)Disconnect the ammeter and voltmeter.
(18)Connect the alternator output wire to the
alternator “B” terminal.
(19)Connect the negative battery cable.