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.
SYS.OK|MANUAL.DB● LIVE
HOMESERVICE MANUALSMITSUBISHI2005LANCER EVOLUTION L4-2.0L DOHC TURBOREPAIR AND DIAGNOSISSTARTING AND CHARGINGCHARGING SYSTEMALTERNATORSERVICE AND REPAIRDISASSEMBLY AND ASSEMBLY
2005 Mitsubishi Lancer Evolution L4-2.0L DOHC Turbo
Disassembly and Assembly
2005 Mitsubishi Lancer Evolution L4-2.0L DOHC TurboSECTION Disassembly and Assembly
GENERATOR ASSEMBLY
DISASSEMBLY AND ASSEMBLY
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, to prevent damaging 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
<> REGULATOR ASSEMBLY 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 assists installation of the rotor.
<> ROTOR INSTALLATION
Remove the brush holding wire after the rotor has been installed.
RECTIFIER ASSEMBLY
1. Check the condition of the (+) heat sink by checking continuity between the (+) heat sink and each of the stator coil lead connecting terminals.
If continuity is present for both terminals, the diode is shorted. Replace the rectifier assembly.
2. Check the condition of the (-) heat sink by checking continuity between the (-) heat sink and each of the stator coil lead connecting terminals.
If continuity is present in both directions, the diode is shorted. Replace the rectifier assembly.
3. Check the condition of the diode trio by testing continuity of each of the three diodes using a circuit tester connected to both sides of the diode.
If the same reading results for both polarities, the diode is defective. Replace the rectifier assembly if any of the diodes is defective.
BRUSH
1. Measure the length of the protrusion of the brush. Replace the brush if the protrusion length is shorter than the limit.
Limit: 2 mm minimum
2. Unsolder the lead of the brush. The brush will come out, ready for removal.
3. Install a new brush by pushing it into the holder as shown in the drawing and soldering the lead.
Disassembly And Assembly:
DISASSEMBLY AND ASSEMBLY
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, to prevent damaging the rotor.
Clamp the rotor in a vise with the pulley facing up to remove the pulley.
<
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
<> REGULATOR ASSEMBLY 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 assists installation of the rotor.
<> ROTOR INSTALLATION
Remove the brush holding wire after the rotor has been installed.
RECTIFIER ASSEMBLY
1. Check the condition of the (+) heat sink by checking continuity between the (+) heat sink and each of the stator coil lead connecting terminals.
If continuity is present for both terminals, the diode is shorted. Replace the rectifier assembly.
2. Check the condition of the (-) heat sink by checking continuity between the (-) heat sink and each of the stator coil lead connecting terminals.
If continuity is present in both directions, the diode is shorted. Replace the rectifier assembly.
3. Check the condition of the diode trio by testing continuity of each of the three diodes using a circuit tester connected to both sides of the diode.
If the same reading results for both polarities, the diode is defective. Replace the rectifier assembly if any of the diodes is defective.
BRUSH
1. Measure the length of the protrusion of the brush. Replace the brush if the protrusion length is shorter than the limit.
Limit: 2 mm minimum
2. Unsolder the lead of the brush. The brush will come out, ready for removal.
3. Install a new brush by pushing it into the holder as shown in the drawing and soldering the lead.
RENDER: 1.0x
NO RELATED
Recommended Tools & Savings
Use the Manual With the Right Hardware
Pair factory procedures with proven DIY tools so the instructions are easier to execute.
Affiliate disclosure: We may earn a commission at no extra cost to you.
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.