Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSMITSUBISHI2004LANCER L4-2.0L SOHCREPAIR AND DIAGNOSISSTARTING AND CHARGINGCHARGING SYSTEMALTERNATORSERVICE AND REPAIRDISASSEMBLY AND ASSEMBLY
2004 Mitsubishi Lancer L4-2.0L SOHC
Disassembly and Assembly
2004 Mitsubishi Lancer L4-2.0L SOHCSECTION Disassembly and Assembly
GENERATOR ASSEMBLY
DISASSEMBLY SERVICE POINTS
<> FRONT BRACKET ASSEMBLY REMOVAL
CAUTION: Do not insert a screwdriver too deep. The stator coil will be damaged.
Insert a flat-tipped screwdriver between the front bracket assembly and the stator core, and pry it downward to separate the stator and front bracket assembly.
<> GENERATOR PULLEY REMOVAL
CAUTION: Make sure not to damage the rotor.
Set the pulley upward, clamp the rotor in a vise, and remove the pulley.
<> STATOR REMOVAL
CAUTION:
- Check that the heat from the soldering iron is not transmitted to the diode for a long time.
- Use care that no undue force is exerted to leads of diodes.
1. Use a soldering iron (180 to 250 W) to unsolder the stator.
This work should complete within approximately four seconds to prevent heat from transferring to the diode.
2. When removing the rectifier from the regulator assembly, unsolder the points soldered on the rectifier.
ASSEMBLY SERVICE POINTS
>>A<< REGULATOR ASSEMBLY INSTALLATION
After installing the regulator assembly, insert a wire through the hole provided on the rear bracket while pressing down on the brush, and secure the brush.
NOTE: By inserting a wire, the brush will be secured in place, and the installation of the rotor will be easier.
>>B<< ROTOR ASSEMBLY INSTALLATION
After installing the rotor, remove the wire used to secure the brush.
DISASSEMBLY SERVICE POINTS
<> FRONT BRACKET ASSEMBLY REMOVAL
CAUTION: Do not insert a screwdriver too deep. The stator coil will be damaged.
Insert a flat-tipped screwdriver between the front bracket assembly and the stator core, and pry it downward to separate the stator and front bracket assembly.
Generator Pulley Removal:
<> GENERATOR PULLEY REMOVAL
CAUTION: Make sure not to damage the rotor.
Set the pulley upward, clamp the rotor in a vise, and remove the pulley.
Stator/Regulator And Brush Holder Removal:
<
CAUTION:
- Check that the heat from the soldering iron is not transmitted to the diode for a long time.
- Use care that no undue force is exerted to leads of diodes.
1. Use a soldering iron (180 to 250 W) to unsolder the stator.
This work should complete within approximately four seconds to prevent heat from transferring to the diode.
2. When removing the rectifier from the regulator assembly, unsolder the points soldered on the rectifier.
ASSEMBLY SERVICE POINTS
>>A<< REGULATOR ASSEMBLY INSTALLATION
After installing the regulator assembly, insert a wire through the hole provided on the rear bracket while pressing down on the brush, and secure the brush.
NOTE: By inserting a wire, the brush will be secured in place, and the installation of the rotor will be easier.
Rotor Assembly Installation:
>>B<< ROTOR ASSEMBLY INSTALLATION
After installing the rotor, remove the wire used to secure the brush.
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.