Mitsubishi Outlander (2003+). Manual — part 140

STARTING SYSTEM

ENGINE ELECTRICAL

16-25

FREE RUNNING TEST

1. Place the starter motor in a vise equipped with

soft jaws and connect a fully-charged 12-volt
battery to the starter motor as follows:

2. Connect a test ammeter (100-ampere scale) and

carbon pile rheostat in series between the positive
battery terminal and starter motor terminal.

3. Connect a voltmeter (15-volt scale) across the

starter motor.

4. Rotate the rheostat to full-resistance position.
5. Connect the battery cable from the negative

battery terminal to the starter motor body.

6. Adjust the rheostat until the battery positive

voltage shown on the voltmeter is 11 V.

7. Confirm that the maximum amperage is within the

specifications and that the starter motor turns
smoothly and freely.

Current: maximum 95 Amps

MAGNETIC SWITCH RETURN TEST

1. Disconnect the field coil wire from the M-terminal

of the magnetic switch.

CAUTION

This test must be performed quickly (in less than
10 seconds) to prevent the coil from burning.
2. Connect a 12-volt battery between the M-terminal

and body.

WARNING

Be careful not to get your fingers caught
when pulling out the pinion.

3. Pull the pinion out and release. If the pinion

quickly returns to its original position, everything is
operating properly. If it doesn't, replace the
magnetic switch.

AKX01246

S

M

B

Ammeter

Carbon-pile
rheostat

Battery

Starter
motor

Voltmeter

AE

A

V

AKX01248

S

B

M

Battery

Starter
motor

Wire

AE

STARTING SYSTEM

ENGINE ELECTRICAL

16-26

DISASSEMBLY AND REASSEMBLY

M1162001200224

AK304532

2

17

18

19

20

16

14

13

21

3

15

11

12

1

4

6

8

7

9

10

5

5.8 ± 1.6 N·m

5.8 ± 1.6 N·m

3.4 ± 1.0 N·m

AB

Disassembly steps

1. Screw

<<A>>

2. Magnetic switch
3. Screw
4. Bolt
5. Rear bracket
6. Brush holder
7. Rear bearing
8. Armature
9. Yoke assembly
10. Ball
11. Packing A

12. Packing B
13. Plate
14. Planetary gear
15. Lever

<<B>> >>A<<

16. Snap ring

<<B>> >>A<<

17. Stop ring
18. Overrunning clutch
19. Internal gear
20. Planetary gear shaft
21. Front bracket

Disassembly steps (Continued)

STARTING SYSTEM

ENGINE ELECTRICAL

16-27

DISASSEMBLY SERVICE POINTS

<<A>> MAGNETIC SWITCH REMOVAL

CAUTION

Do not clamp the yoke assembly with a vise.
Disconnect the lead from the M terminal of the
magnetic switch.

<<B>> SNAP RING/STOP RING REMOVAL

1. Apply a long socket wrench of an appropriate size

to the stop ring and strike the wrench to drive out
the stop ring toward the pinion gear side.

2. Remove the snap ring with snap ring pliers, then

remove the stop ring and overrunning clutch.

STARTER MOTOR PARTS CLEANING

Never clean in a solvent such starter motor parts as

the magnetic switch, brush holder, and armature.
If they are soaked in a solvent, their insulation
could be impaired. When these parts require
cleaning, wipe off contamination with cloth.

1. Never soak the drive unit in a solvent. If it is

washed in a solvent, the grease having been
packed in the overrunning clutch at the factory will
be washed out. Wipe the drive unit with cloth if it
requires cleaning.

REASSEMBLY SERVICE POINTS

>>A<< STOP RING/SNAP RING INSTALLATION

Use a suitable puller to pull the stop ring until it gets
over the snap ring.

INSPECTION

M1162001300179

COMMUTATOR

1. Support the armature with a pair of V block and

turn it to measure the runout of the surface not
rubbed by the brushes using a dial gauge.

Standard value: 0.05 mm or less
Limit: 0.1 mm

AK202890

B terminal

M terminal

S terminal

Field coil
lead

AB

AK202790

Socket wrench

Stop ring

Pinion Gear

Overrunning
clutch

AB

AK202791

Snap ring
pliers

Snap ring

Pinion gear

Overrunnning
clutch

AB

AK202911

Overrunning
clutch

Stop ring

Snap ring

Stop ring

AB

AK202712

STARTING SYSTEM

ENGINE ELECTRICAL

16-28

2. Measure the diameter of the commutator.

Standard value: 29.4 mm
Limit: 28.8 mm

3. Measure the depth of the undercut between

segments.

Standard value: 0.5 mm
Limit: 0.2 mm

BRUSH HOLDER

Push the brush into the brush holder to make sure
that the spring is working on the brush.
If the spring is not working, replace the brush holder.

OVERRUNNING CLUTCH

1. Make sure that the pinion cannot be turned

counterclockwise and can be turned clockwise
freely.

2. Check the pinion for abnormal ware and damage.

BRUSHES

1. Check the commutator contacting surface of each

brush for abnormal roughness. Also check the
height of the brush. Replace the brush holder if
the height is lower than the limit.

Limit: 7.0 mm

2. When the contact surface of the brush is rectified

or the brush holder is replaced, recondition the
contact surface with sandpaper wrapped around
the commutator.

AK202715

AK202711

Segment

Undercut

Mica

AB

AK202897

AK202710

Free

Lock

AB

AK202846

Brush
height

AB