Mitsubishi Montero (2002-2004). Manual — part 1087

STARTING SYSTEM

TSB Revision

ENGINE ELECTRICAL

16-21

INSPECTION

M1162001100023

.

PINION GAP ADJUSTMENT
1. Disconnect the field coil wire from the M-terminal of the

magnetic switch.

2. Connect a 12-volt battery between the S-terminal and M-

terminal.

CAUTION

This test must be performed quickly (in less than 10 sec-
onds) to prevent the coil from burning.
3. Set the switch to "ON", and the pinion will move out.

4. Check the pinion-to-stopper clearance (pinion gap) with a

feeler gauge.

Standard value: 0.5

− 2.0 mm (0.02 − 0.07 inch)

5. If the pinion gap is out of specification, adjust by adding or

removing gasket(s) between the magnetic switch and front
bracket.

.

MAGNETIC SWITCH PULL-IN 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 sec-
onds) to prevent the coil from burning.
2. Connect a 12-volt battery between the S-terminal and M-

terminal.

3. If the pinion moves out, the pull-in coil is good. If it doesn't,

replace the magnetic switch.

.

AKX00197

SWITCH

S

B

M

WIRE

STARTER
MOTOR

BATTERY

AB

AKX00198

STOPPER

PINION GAP

PINION

AB

AKX00199

AKX00200

S

B

M

WIRE

STARTER
MOTOR

BATTERY

AB

STARTING SYSTEM

TSB Revision

ENGINE ELECTRICAL

16-22

MAGNETIC SWITCH HOLD-IN 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 sec-
onds) to prevent the coil from burning.
2. Connect a 12-volt battery between the S-terminal and body.
3. Manually pull out the pinion as far as the pinion stopper

position.

4. If the pinion remains out, everything is operating properly. If

the pinion moves in, the hold-in circuit is open. Replace the
magnetic switch.

.

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 carbon pile 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

by 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 90 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 sec-
onds) 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.

AKX00201

S

B

M

WIRE

STARTER
MOTOR

BATTERY

AB

AKX00202

S

B

M

STARTER
MOTOR

BATTERY

AMMETER

VOLTMETER

CARBON-PILE
RHEOSTAT

AB

AKX00203

S

B

M

WIRE

STARTER
MOTOR

BATTERY

AB

STARTING SYSTEM

TSB Revision

ENGINE ELECTRICAL

16-23

DISASSEMBLY AND ASSEMBLY

M1162001200075

AK101266

2

17

18

19

20

16

14

13

21

3

15

11

12

1

4

6

8

7

9

10

AB

5

5.8 ± 1.6 N·m
52 ± 14 in-lb

5.8 ± 1.6 N·m
52 ± 14 in-lb

3.4 ± 1.0 N·m
30 ± 9 in-lb

DISASSEMBLY STEPS

1. SCREW
2. MAGNETIC SWITCH
3. SCREW
4. SCREW
5. REAR BRACKET
6. BRUSH HOLDER ASSEMBLY
7. REAR BEARING

<<A>>

8. ARMATURE
9. YOKE ASSEMBLY

<<A>>

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 HOLDER
21. FRONT BRACKET

DISASSEMBLY STEPS

STARTING SYSTEM

TSB Revision

ENGINE ELECTRICAL

16-24

DISASSEMBLY SERVICE POINTS

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<<A>> ARMATURE AND BALL REMOVAL

CAUTION

When removing the armature, take care not to lose the ball
(which is used as a bearing) in the armature end.

.

<<B>> SNAP RING AND STOP RING REMOVAL
1. Press a long socket wrench of appropriate size to the stop

ring. Then tap the socket wrench to remove the stop ring to
the pinion gear side.

2. After removing the snap ring (by using snap-ring pliers),

remove the stop ring and the overrunning clutch.

STARTER MOTOR PART CLEANING

1. Do not immerse parts in cleaning solvent. Immersing the

yoke and field coil assembly and/or armature will damage
insulation. Wipe these parts with a shop towel only.

2. Do not immerse the drive unit in cleaning solvent.

Overrunning clutch is pre-lubricated at the factory and
solvent will wash lubrication from the clutch.

3. The drive unit may be cleaned with a brush moistened with

cleaning solvent and wiped dry with a shop towel.

ASSEMBLY SERVICE POINT

.

>>A<< STOP RING AND SNAP RING INSTALLATION
Using a suitable pulling tool, pull the overrunning clutch stop
ring over the snap ring.

AKX00370

SOCKET

STOP RING

PINION GEAR

OVERRUNNING
CLUTCH

AB

AKX00371

SNAP RING

PINION GEAR

OVERRUNNING
CLUTCH

SNAP-RING
PLIERS

AB

AKX00372

STOP RING

OVERRUNNING
CLUTCH

SNAP RING

STOP
RING

AB