2007 MITSUBISHI LANCER EVOLUTION engine

ENGINE ELECTRICAL -Charging System16-7
REGULATED VOLTAGE TEST
B
BlueRed
Ignition
switchLoad
FR
L
S
GMB991519
Alternator
BatteryVoltmeterAmmeter
Yellow
Engine-ECU
Black
This test determines whether the voltage regulator
is correctly controlling the alternator output voltage.
(1) Always be sure to check the following before
the test.
DAlternator installation
DCheck that the battery installed in the
vehicle is fully charged.
(Refer to GROUP 54 - Battery.)
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) Use the special tool (Alternator test harness:
MB991519) to connect a digital voltmeter
between the alternator S terminal and earth.
(Connect the (+) lead of the voltmeter to the
“S” terminal, and then connect the (−) lead of
the voltmeter to a secure earth or to the battery
(−) terminal.)
(5) Disconnect the alternator output wire from the
alternator “B” terminal.(6) 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.)
(7) Reconnect the negative battery cable.
(8) Connect a tachometer or the MUT-II. (Refer
to GROUP 11 - On-vehicle Service.)
(9) Turn the ignition switch to the ON position and
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 “S” terminal and the battery (+)
terminal.
(10)Turn all lamps and accessories off.
(11) Start the engine.
(12)Increase the engine speed to 2,500 r/min.
(13)Read the value displayed on the voltmeter when
the alternator output current alternator
becomes 10 A or less.

ENGINE ELECTRICAL -Charging System16-8
(14)If the voltage reading conforms to the value
in the voltage regulation, then the voltage
regulator is operating normally.
If the voltage is not within the standard value,
there is a malfunction of the voltage regulator
or of the alternator.
(15)After the test, lower the engine speed to the
idle speed.
(16)Turn the ignition switch to the “LOCK” (OFF)
position.(17)Remove the tachometer or the MUT-II.
(18)Disconnect the negative battery cable.
(19)Disconnect the ammeter and voltmeter.
(20)Connect the alternator output wire to the
alternator “B” terminal.
(21)Remove the special tool, and return the
connector to the original condition.
(22)Connect the negative battery cable.
Voltage Regulation Table
Standard value:
Inspection terminalVoltage regulator ambient temperature_CVoltage V
Terminal “S”-2014.2 - 15.4
2013.9 - 14.9
6013.4 - 14.6
8013.1 - 14.5
WAVEFORM CHECK USING AN ANALYZER
MEASUREMENT METHOD
Connect the analyzer special patterns pick-up to the alternator
B terminal.
STANDARD WAVEFORM
Observation Conditions
FUNCTIONSPECIAL PATTERNS
PATTERN HEIGHTVARIABLE
VARIABLE knobAdjust while viewing the wave-
form.
PATTERN SELECTORRASTER
Engine speedCurb idle speed
AlternatorSpecial
patterns
pickupAnalyzer
B terminal

ENGINE ELECTRICAL -Charging System16-9
Voltage at
alternator
B terminal0.4
0.2
0
- 0.2
- 0.4
Time
NOTE
The voltage waveform of the alternator B terminal can undulate
as shown at left. This waveform is produced when the regulator
operates according to fluctuations in the alternator load
(current), and is normal for the alternator.
In addition, when the voltage waveform reaches an
excessively high value (approximately 2 V or higher at idle),
it often indicates an open circuit due to a brown fuse between
alternator B terminal and battery, but not a defective alternator.

ENGINE ELECTRICAL -Charging System16-10
EXAMPLES OF ABNORMAL WAVEFORMS
NOTE
1. The size of the waveform patterns differs largely, depending on the adjustment of the variable knob
on the analyzer.
2. Identification of abnormal waveforms is easier when there is a large output current (regulator is not
operating). (Waveforms can be observed when the headlamps are illuminated.)
3. Check the conditions of the charging warning lamp (illuminated/not illuminated). Also, check the charging
system totally.
Abnormal waveformsProblem
causeAbnormal waveformsProblem
cause
Example 1Open diodeExample 4Short in
stator coil
Example 2Short in diodeExample 5Open
supplementa-
ry diode
Example 3Broken wire
in stator coil
At this time, the charging warning lamp
is illuminated.
ALTERNATOR
REMOVAL AND INSTALLATION
Caution
If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact
the parts or tools to the caliper because the paint of caliper will be scratched.
Pre-removal and Post-installation Operation
DUnder Cover Removal and Installation (Refer to GROUP 51 - Front Bumper.)
DDrive Belt Tension Check (Refer to GROUP 11A - On-vehicle Service.)
DStrut Tower Bar Removal and Installation (Refer to GROUP 42.)
DCrossmember Bar Removal and Installation (Refer to GROUP 32 - Engine Roll Stopper, Centermember.)
DFront Exhaust Pipe Assembly Removal and Installation (Refer to GROUP 15.)

ENGINE ELECTRICAL -Charging System16-11
1
234
5
8.8±1.0 N·m 22±4 N·m
23±3 N·m11±1 N·m
13±1 N·m
8
(Engine oil)
679
10
20±2 N·m 36±6 N·m
1211
44±10 N·m
14±3 N·m
13
1415 18
1617
9.0±1.0 N·m
9.0±1.0 N·m5.0±1.0 N·m
Removal steps
1. Oil level gauge and guide assembly
2. O-ring
3. Fuel pressure solenoid valve
connector
4. Fuel pressure solenoid valve
assembly
5. Detonation sensor connector
6. Purge control solenoid valve
connector
7. Purge control solenoid valve assembly
8. Injector connector
AA"9. Delivery pipe, injector, and fuel
pressure regulator assembly10. Insulator
11. Insulator
AB"12. Drive belt
13. Alternator connector
DEngine mounting
(Refer to GROUP 32.)
AC"14. Alternator
15. Water pump pulley
16. Alternator brace
17. Oxygen sensor connector
18. Alternator brace stay

ENGINE ELECTRICAL -Charging System16-12
REMOVAL SERVICE POINTS
AA"DELIVERY PIPE, INJECTOR, AND FUEL
PRESSURE REGULATOR ASSEMBLY REMOVAL
After loosening the installed parts, set the related parts
aside to make some space for removing the alternator.
AB"DRIVE BELT REMOVAL
Due to the adoption of the Serpentine drive system with
the auto-tensioner, the following operation is required:
1. Insert the 12.7sq. spinner handle into the tool hole of
the auto-tensioner and rotate it counterclockwise until
the auto-tensioner reaches to the stopper.
2. Align hole A with hole B for fixing by inserting the L-shaped
hexagon wrench, then remove the drive belt.
Caution
When the drive belt is reused, use a chalk to
indicate an arrow of rotation direction on the
back of the belt so that it can be re-assembled in
the same direction as before.
AC"ALTERNATOR REMOVAL
Push up the engine with a garage jack to the top and
remove the alternator upward from the engine room.
Hole A
L-shaped
hexagon
wrench
Hole B

ENGINE ELECTRICAL -Charging System16-13
DISASSEMBLY AND REASSEMBLY
1
23
4 7654
891012
111314
Disassembly steps
AA"1. Front bracket assembly
AB"2. Alternator pulley
"BA3. Rotor
4. Rear bearing
5. Bearing retainer
6. Front bearing
7. Front bracketAC"8. Stator
9. Plate
AC""AA10. Regulator assembly
11. Brush
12. Packing
13. Rectifier
14. Rear bracket

ENGINE ELECTRICAL -Charging System16-14
DISASSEMBLY SERVICE POINTS
AA"FRONT 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 a screwdriver too far, or the stator coil gets
damaged.
AB"ALTERNATOR 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.
AC"STATOR/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
"AAREGULATOR 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.
SolderedRectifier
assembly
Soldered
Wire
Rear bracket
BrushWire