starter MITSUBISHI MONTERO 1998 Owner's Manual
Page 1084 of 1501
smoothly. See STARTER NO-LOAD TEST SPECIFICATIONS table.
Fig. 2: Performing Starter No-Load Test
Courtesy of Mitsubishi Motor Sales of America
STARTER NO-LOAD TEST SPECIFICATIONS TABLE
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(1) Starter Test Maximum Amps @
Application Type Voltage Minimum RPM
Diamante ............... GR .... 12.0 ..... 110 @ 5000
Eclipse
2.0L Non-Turbo ....... DD .... 11.5 ............ ( 2)
2.0L Turbo & 2.4L .... GR .... 11.0 ...... 90 @ 3000
Galant, Montero
& 3000GT .............. GR .... 11.0 ...... 90 @ 3000
Mirage
1.5L & 1.8L M/T ...... DD .... 11.5 ...... 60 @ 6000
1.8L A/T & M/T ....... GR .... 11.0 ...... 90 @ 2800
Montero Sport .......... GR ..... 12 ............. ( 2)
( 1) - DD indicates direct drive. GR indicates gear
reduction.
( 2) - Information is not available from manufacturer at time
of publication.
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PULL-IN COIL TEST
1) Disconnect field coil wire from terminal "M" at starter
solenoid. See Fig. 3. Connect jumper wire between positive battery
terminal of 12-volt battery and terminal "S" of solenoid.
2) Connect a second jumper wire from negative battery
terminal and touch terminal "M" of starter solenoid. If solenoid
plunger moves inward, solenoid is good. If solenoid plunger does not
move inward, replace solenoid.
Page 1085 of 1501
Fig. 3: Identifying Starter Solenoid Terminals
Courtesy of Mitsubishi Motor Sales of America
HOLD-IN COIL TEST
1) Disconnect field coil wire from terminal "M" at starter
solenoid. See Fig. 3. Connect jumper wire between positive battery
terminal of 12-volt battery and terminal "S" of starter solenoid.
2) Connect a second jumper wire from negative battery
terminal and touch starter case. If solenoid plunger is pulled in,
hold-in coil is good. If solenoid plunger is not pulled in, replace
solenoid.
PINION RETURN TEST
1) Disconnect field coil wire from terminal "M" at starter
solenoid. See Fig. 3. Connect jumper wire between positive battery
terminal of 12-volt battery and terminal "M" of starter solenoid.
2) Connect a second jumper wire from negative battery
terminal and touch starter case. Pull pinion outward and release it.
Replace solenoid if pinion remains out.
PINION GAP MEASUREMENT
1) Disconnect field coil wire from terminal "M" at starter
solenoid. See Fig. 3. Connect jumper wire between positive battery
terminal of 12-volt battery and terminal "S" of starter solenoid.
2) Connect a second jumper wire from negative battery
terminal and touch terminal "M" of starter solenoid. Using a feeler
gauge, measure clearance between pinion and stopper. See Fig. 4.
3) Clearance should be within specification. See
STARTER SPECIFICATIONS table. Adjust clearance by adding or removing
gaskets between solenoid and front housing.
Page 1087 of 1501
ARMATURE TEST
Ensure armature is not grounded. Place armature in growler.
Hold a thin steel blade parallel and just above armature while slowly
rotating armature in growler. A shorted armature will cause blade to
vibrate and be attracted to core. Using an ohmmeter, check continuity
between armature coil cores and commutator segments (small diameter
end of armature). Continuity should not exist. Check for continuity
between segments. Continuity should exist. Replace armature as
necessary.
BRUSH HOLDER TEST
Using an ohmmeter, check continuity between brush holder
plate and brush holder. Continuity should not exist. Replace brush
holder as necessary.
REMOVAL & INSTALLATION
NOTE: On Montero with A/T, it may be necessary to disconnect
transmission oil cooler line for starter removal.
Removal & Installation
Disconnect negative battery cable. If necessary, raise
vehicle on hoist. Remove starter mounting bolts and starter. To
install, reverse removal procedure.
OVERHAUL
Check commutator for out-of-round and proper amount of
undercut. Replace or repair armature if not within specification. See
STARTER SPECIFICATIONS table. Ensure brushes are not worn beyond wear
line (outer line closest to commutator contact surface). Check pinion
gap. See PINION GAP MEASUREMENT under BENCH TESTING. See Figs. 5 and
6.
Fig. 5: Exploded View Of Direct Drive Starter (Typical)
Courtesy of Mitsubishi Motor Sales of America
Page 1088 of 1501
Fig. 6: Exploded View Of Gear Reduction Starter (Typical)
Courtesy of Mitsubishi Motor Sales of America
STARTER SPECIFICATIONS
Page 1089 of 1501
STARTER SPECIFICATIONS TABLE \
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Application In. (mm)
Commutator Maximum Runout ..................... .004 (.10)
Commutator Minimum Diameter
Diamante ................................... 1.23 (31.2)
Eclipse
Direct Drive Type ................................ (1)
Gear Reduction Type ...................... 1.12 (28.4)
Galant ..................................... 1.12 (28.4)
Mirage
Direct Drive Type ........................ 1.22 (31.4)
Gear Reduction Type ...................... 1.12 (28.4)
Montero & Montero Sport .................... 1.13 (28.8)
3000GT ..................................... 1.12 (28.4)
Commutator Undercut Depth ..................... .020 (.51)
Pinion Gap .......................... .020-.079 (.51-2.01)
( 1) - Information is not available from manufacturer at time
of publication.
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TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS TABLE \
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Application Ft. Lbs. (N.m)
Starter-To-Block Bolts
Diamante ....................................... 23 (31)
Eclipse
2.0L Non-Turbo ............................... 40 (54)
2.0L Turbo & 2.4L ............................ 22 (30)
Galant ......................................... 22 (30)
Mirage ......................................... 36 (49)
Montero & Montero Sport .................. 19-24 (26-33)
3000GT ......................................... 23 (31)
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WIRING DIAGRAMS
Page 1354 of 1501
TRANSMISSION REMOVAL & INSTALLATION - A/T
1998 Mitsubishi Montero
1997-98 TRANSMISSION SERVICING
Mitsubishi Transmission Removal & Installation
Diamante, Eclipse, Galant, Mirage, Montero, 3000GT
REMOVAL & INSTALLATION
AWD & FWD MODELS
Removal
1) On all models except Galant, remove battery and battery
tray. On 3000GT, remove washer tank. On all models, remove air cleaner
cover with air inlet hose assembly. Raise and support vehicle. Remove
wheels. Remove undercover(s) (if equipped). Disconnect control cable\
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at transaxle. Drain transaxle fluid.
2) On AWD models, remove front exhaust pipe. On all models,
disconnect neutral safety switch connector, oil cooler hoses and
electrical connectors from transaxle. Disconnect speedometer cable and
throttle control cable (if equipped). Remove starter motor.
3) Separate tie rod end. Separate lower ball joint. Separate
stabilizer bar connection (if necessary). Remove axle shafts. See
appropriate AXLE SHAFTS article in DRIVE AXLES. Remove center
crossmember assembly.
4) On AWD models, separate transfer assembly from transaxle.
Reference mark transfer assembly-to-drive shaft and remove transfer
assembly.
5) On all models, remove transmission inspection (dust)
cover. Place index mark on torque converter and drive plate for
reassembly reference. Remove torque converter-to-drive plate bolts.
Push torque converter away from engine into transaxle.
6) On all 4-cylinder models, support engine. On all models,
support transaxle with jack. Remove bolts from transaxle mounts.
Remove mounting brackets and remaining transaxle-to-engine bolts.
Slide transaxle assembly to right and lower to remove.
CAUTION: Ensure torque converter is fully seated in transaxle before
installation. Always install new snap rings on inner
constant velocity joints.
Installation
1) To install, reverse removal procedure. Tighten transaxle-
to-engine bolts and torque converter-to-drive plate bolts to
specification. See TORQUE SPECIFICATIONS .
2) Ensure reference marks on torque converter-to-drive plate
and transfer assembly-to-drive shaft align. Tighten mounting bolts
with weight of engine and transaxle on mounts. Refill transaxle fluid
to specified level. See LUBRICATION in TRANSMISSION SERVICING - A/T
article. Adjust all control cables. See ADJUSTMENTS in
TRANSMISSION SERVICING - A/T article.
RWD & 4WD MODELS
Removal
1) Disconnect negative battery cable. On Montero 4WD, remove
transfer case shift lever knob, dust boot and retainer plate or
console. Remove transfer case gearshift assembly.
2) On all models, raise and support vehicle. Remove
undercarriage cover and/or skid plate(s). Drain transmission and
transfer case (if applicable). Place reference mark on drive shaft(s)\
Page 1355 of 1501
and remove. Disconnect all external solenoid and switch connections.
3) On Montero 4WD, remove catalytic converter and front
exhaust pipe. On all models, disconnect speedometer cable and control
cables at transmission. Remove starter and bellhousing cover. Place
reference mark on torque converter and drive plate for reassembly
reference. Remove torque converter bolts. Push torque converter back
and away from drive plate.
4) Disconnect transmission cooler lines. Remove oil filler
tube. Secure transmission on a jack. Raise transmission slightly to
take weight off mount. Remove crossmember-to-mount bolts and
crossmember.
5) Remove transfer case mounting bracket and mount (if
equipped). Remove transmission-to-engine mounting bolts. Carefully
lower transmission from vehicle.
CAUTION: Ensure torque converter is fully seated in transmission
before installation.
Installation
1) To install, reverse removal procedure. Tighten
transmission-to-engine bolts and torque converter-to-drive plate bolts
to specification. See TORQUE SPECIFICATIONS. Tighten mount bolts with
weight of engine and transmission on mounts. Ensure reference marks on
drive shaft(s) and torque converter-to-drive plate are matched.
2) Apply sealant to transfer case gearshift assembly gasket
before installation. Coat transmission oil filler tube "O" ring with
transmission fluid before installation. Refill transmission fluid to
specified level. See LUBRICATION in TRANSMISSION SERVICING - A/T
article. Adjust all control cables. See ADJUSTMENTS in
TRANSMISSION SERVICING - A/T article.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS - FWD MODELS \
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Applications Ft. Lbs. (N.m)\
Ball Joint Nut ............................................ 74 (100)\
Center Crossmember Assembly Front Bolt ..................... 69 (93)\
Center Crossmember Assembly Rear Bolt ...................... 52 (70)\
Starter Bolts .............................................. 22 (30)\
Tie Rod End Nut ............................................ 21 (28)\
Torque Converter-To-Drive Plate Bolt ................. 33-38 (45-52)\
Transaxle-To-Engine Block Bolt
8-mm Bolt .................................................... ( 1)
10-mm Bolt ......................................... 22-25 (30-34)\
12-mm Bolt ......................................... 31-40 (42-54)\
Upper Coupling Bolts
2.4L ..................................................... 35 (48)\
3.0L ..................................................... 54 (73)\
Lower Coupling Bolts
2.4L ..................................................... 35 (48)\
3.0L ..................................................... 65 (88)\
( 1) - Tighten to 84-108 INCH lbs. (10-12 N.m).
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TORQUE SPECIFICATIONS - RWD MODELS \
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Applications Ft. Lbs. (N.m)\
Engine-To-Transmission Bolt ................................ 65 (88)\
Page 1370 of 1501
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OK NOT OK
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* Check Pick-Up coil for * Adjust or replace as
correct resistance value. necessary.
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NOT OK OK
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* Replace Pick-Up coil if * Check control module for
not to specification. good ground connections.
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OK
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* If vehicle fails to run at this point, go to
the appropriate article in the ENGINE
PERFORMANCE section.
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OK NOT OK
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* Check wires from the battery/ * Replace ballast resistor
ignition switch to the coil. if the measured resistance
Also check the coil primary value is not within
and secondary resistance. specification.
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STARTER TROUBLE SHOOTING
NOTE: This is GENERAL information. This article is not intended
to be specific to any unique situation or individual vehicle
configuration. The purpose of this Trouble Shooting
information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting,
refer to SUBJECT, DIAGNOSTIC, or TESTING articles available
in the section(s) you are accessing.
BASIC STARTER TROUBLE SHOOTING CHART
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CONDITION POSSIBLE CAUSE CORRECTION \
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Starter Fails Dead battery or bad Check battery charge
to Operate connections between and all wires and
starter and battery connections to starter
Ignition switch faulty Adjust or replace
or misadjusted ignition switch
Open circuit between Check and repair wires
starter switch ignition and connections as
terminal on starter relay necessary
Starter relay or starter See Testing in STARTER
defective article
Page 1371 of 1501
Open solenoid pull-in See Testing in STARTER
wire article
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Starter Does Not Weak battery or dead Charge or replace
Operate and cell battery as necessary
Headlights Dim
Loose or corroded battery Check that battery
connections connections are clean
and tight
Internal ground in See Testing in STARTER
starter windings article
Grounded starter fields See Testing in STARTERS
Armature rubbing on pole See STARTER article
shoes
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Starter Turns Starter clutch slipping See STARTER article
but Engine
Does Not Rotate
Broken clutch housing See STARTER article
Pinion shaft rusted or See STARTER article
dry
Engine basic timing See Ignition Timing in
incorrect TUNE-UP article
Broken teeth on engine Replace flywheel and
flywheel check for starter pinion
gear damage
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Starter Will Not Faulty overrunning See STARTER article
Crank Engine clutch
Broken clutch housing See STARTER article
Broken flywheel teeth Replace flywheel and
check for starter pinion
gear damage
Armature shaft sheared See STARTER article
or reduction gear teeth
stripped
Weak battery Charge or replace
battery as necessary
Faulty solenoid See On-Vehicle Tests in
STARTER article
Poor grounds Check all ground
connections for
tight and clean
connections
Ignition switch faulty Adjust or replace
or misadjusted ignition switch as
necessary
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Starter Cranks Battery weak or Charge or replace
Engine Slowly defective battery as necessary
Page 1372 of 1501
Engine overheated See ENGINE COOLING
SYSTEM article
Engine oil too heavy Check that proper
viscosity oil
is used
Poor battery-to-starter Check that all
connections between
battery and starter are
clean and tight
Current draw too low or See Bench Tests in
too high STARTER article
Bent armature, loose pole See STARTER article
shoes screws or worn
bearings
Burned solenoid contacts Replace solenoid
Faulty starter Replace starter
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Starter Engages Engine timing too far See Ignition Timing in
Engine Only advanced TUNE-UP article
Momentarily
Overrunning clutch not Replace overrunning
engaging properly clutch. See STARTER
article
Broken starter clutch See STARTER article
Broken teeth on engine Replace flywheel and
flywheel check starter pinion
gear for damage
Weak drive assembly See STARTER article
thrust spring
Weak hold-in coil See Bench Tests in
STARTER article
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Starter Drive Defective point assembly See Testing in STARTER
Will Not Engage article
Poor point assembly ground See Testing in STARTER
article
Defective pull-in coil Replace starter
solenoid
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Starter Relay Dead battery Charge or replace
Does Not Close battery as necessary
Faulty wiring Check all wiring and
connections leading to
relay
Neutral safety switch Replace neutral safety
faulty switch
Starter relay faulty Replace starter relay