Mitsubishi Outlander XL. Manual — part 445

ON-VEHICLE SERVICE

STARTER RELAY CHECK

M11602000014USA0000010000

ZC601035

ZC6028360000

4

2

3

1

1

2

3

4

Starter relay

BATTERY
VOLTAGE

TERMINAL NO. TO
BE CONNECTED TO
TESTER

CONTINUITY TEST
RESULTS

Not applied

4 - 3

Open circuit

Connect
terminal No.2
to battery (+)
terminal.
Connect
terminal No.1
to battery (-)
terminal.

4 - 3

Continuity (less than 2
ohms)

STARTER MOTOR ASSEMBLY

REMOVAL AND INSTALLATION

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Pre-removal and Post-installation Operation
Under Cover Removal and Installation (Refer to GROUP 51A, Under Cover P.51A-18).

STARTING SYSTEM

16b-5

ON-VEHICLE SERVICE

ZC600535

1

2

3

36 ± 9 N·m
27 ± 6 ft-lb

5.0 ± 1.0 N·m
44 ± 9 in-lb

5.0 ± 1.0 N·m
44 ± 9 in-lb

11 ± 1 N·m
93 ± 13 in-lb

AA00

36 ± 9 N·m
27 ± 6 ft-lb

Removal steps

1.

Starter connector and terminal

2.

Starter cover

Removal steps

<<A>>

3.

Starter assembly

REMOVAL SERVICE POINT

<<A>> STARTER ASSEMBLY REMOVAL
Remove the starter assembly from under the vehicle.

INSPECTION

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PINION GAP ADJUSTMENT

ZK600358AA00

Switch

S

M

Wire

Battery

Starter
motor

B

1.

Disconnect the lead wire from the M-terminal of the magnetic
switch.

2.

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

This test must be performed quickly (in less than 10
seconds) to prevent the coil from burning.

3.

Set the switch to "ON", and the pinion will move out.

16b-6

STARTING SYSTEM

STARTER MOTOR ASSEMBLY

ZK600359

Stopper

Pinion gap

Pinion

AA00

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)

ZK600360AA00

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

ZK600361AA00

S

M

Wire

Battery

Starter
motor

B

1.

Disconnect the field coil wire from the M-terminal of the
magnetic switch.

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 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.

MAGNETIC SWITCH HOLD-IN TEST

ZK600362AA00

S

M

Wire

Battery

Starter
motor

B

1.

Disconnect the field coil wire from the M-terminal of the
magnetic switch.

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 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.

STARTING SYSTEM

16b-7

STARTER MOTOR ASSEMBLY

FREE RUNNING TEST

ZK600363AA00

S

A

M

V

B

Carbon-pile rheostat

Battery

Voltmeter

Ammeter

Starter
motor

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

ZK600364AA00

S

M

Wire

Battery

Starter
motor

B

1.

Disconnect the field coil wire from the M-terminal of the
magnetic switch.

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.

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.

DISASSEMBLY AND ASSEMBLY

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16b-8

STARTING SYSTEM

STARTER MOTOR ASSEMBLY