Mitsubishi Outlander GS45X. Manual — part 534
STARTING SYSTEM
TSB Revision
ENGINE ELECTRICAL
16-35
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.
.
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.
.
AKX01243
B
M
S
Battery
Starter
motor
Wire
AK
<2.4L engine>
AK305043AH
S
M
Wire
Battery
Starter
motor
B
<3.0L engine>
AKX01245
B
M
S
Battery
Starter
motor
Wire
AK
<2.4L engine>
AK305044AH
S
M
Wire
Battery
Starter
motor
B
<3.0L engine>
STARTING SYSTEM
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ENGINE ELECTRICAL
16-36
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.
AKX01247
S
M
B
Ammeter
Carbon-pile
rheostat
Battery
Starter
motor
Voltmeter
AK
A
V
<2.4L engine>
AK305045AH
S
A
M
V
B
Carbon-pile rheostat
Battery
Voltmeter
Ammeter
Starter
motor
<3.0L engine>
AKX01249
B
M
S
Battery
Starter
motor
Wire
AK
<2.4L engine>
AK305046AH
S
M
Wire
Battery
Starter
motor
B
<3.0L engine>
STARTING SYSTEM
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ENGINE ELECTRICAL
16-37
DISASSEMBLY AND REASSEMBLY
M1162001200600
AK501908AD
2
16
17
18
19
15
13
12
20
4
14
11
1
5
6
8
7
9
10
3
5.8 ± 1.6 N·m
51 ± 14 in-lb
3.4 ± 1.0 N·m
30 ± 9 in-lb
5.8 ± 1.6 N·m
51 ± 14 in-lb
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. Packing A
11. Packing B
12. Plate
13. Planetary gear
14. Lever
<<
B>> >>A
<< 15. Snap ring
<<
B>> >>A
<< 16. Stop ring
17. Overrunning clutch
18. Internal gear
19. Planetary gear shaft
20. Front bracket
Disassembly steps (Continued)
STARTING SYSTEM
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ENGINE ELECTRICAL
16-38
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
.
1. 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.
2. 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.
AK301505AF
Magnetic
stitch
B terminal
S terminal
Field coil
lead
M terminal
AK304685
Socket wrench
Stop ring
Pinion Gear
Overrunning
clutch
AE
AK304686
Snap ring
pliers
Snap ring
Pinion gear
Overrunning
clutch
AE
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