Engine electrical MITSUBISHI LANCER 2005 Owner's Manual

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Page 84 of 788

MITSUBISHI LANCER 2005 Owners Manual STARTING SYSTEM
ENGINE ELECTRICAL16-20
STARTER MOTOR SPECIFICATIONS
SERVICE SPECIFICATIONS
M1162000300068
Item 4G1 4G6
Type Reduction drive with planetary
gearReduction drive with planetary gear
Rate

Page 85 of 788

MITSUBISHI LANCER 2005 Owners Manual STARTING SYSTEM
ENGINE ELECTRICAL16-21
STARTER MOTOR ASSEMBLY
REMOVAL AND INSTALLATION <4G1>M1162001000628
REMOVAL SERVICE POINT
<<A>> SHIFT CABLE AND SHIFT CABLE
BRACKET ASSEMBLY <M/T> REMOVAL
Remov

Page 86 of 788
STARTING SYSTEM
ENGINE ELECTRICAL16-22
REMOVAL AND INSTALLATION <4G6>M1162001000617
REMOVAL SERVICE POINT
<> STARTER ASSEMBLY REMOVAL
Remove the starter assembly from above the
vehicle.
Pre-removal and Post-installation Operation
•Air Cleaner Assembly Removal and Installation (Refer to
GROUP 15 P.15-3).
•Under Cover Removal and Installation
AC304005
521
6
49 ± 9 N·m 18 ± 3 N·m9.0 ± 2.0 N·m
30 ± 3 N·m
AB
4
3
Removal steps
1. Starter cover
2. Starter connector and terminal
3. Clutch release cylinder connecting
bolts4. Clutch hose clamp
<>5. Starter assembly
6. Starter cover bracketRemoval steps (Continued)

Page 87 of 788
STARTING SYSTEM
ENGINE ELECTRICAL16-23
STARTER MOTOR ASSEMBLY INSPECTIONM1162001100205
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 seconds) 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 mm5. 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 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.
AK300648AB
<4G1>
Switch
S
M
Wire
Battery Starter
motor B
AKX01238
<4G6>
B MS
batterySwitch
Starter
motorWire
AG
AKX00198
Stopper
Pinion gap Pinion
AC
AKX00199
AK300649AB
<4G1>
S
M
Wire
Battery Starter
motor B
AKX01242
<4G6>
S
B M
Battery
Starter
motorWire
AF

Page 88 of 788
STARTING SYSTEM
ENGINE ELECTRICAL16-24
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 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 in order. 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 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 battery (-)
terminal to the starter motor body.
6. Adjust the rheostat until the battery 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:
<4G1> maximum 95 Amps
<4G6> maximum 90 Amps
AK300650AB
<4G1>
S
BMWire
Battery Starter
motor
AKX01244
<4G6>
S
B M
Battery
Starter
motorWire
AF
AK300651AB
<4G1>
S
A M
V BCarbon-pile rheostat
Battery
VoltmeterAmmeter
Starter
motor
AKX01246
<4G6>
S
M
BAmmeter
Carbon-pile
rheostat
Battery
Starter
motor
Voltmeter
AF
A
V

Page 89 of 788
STARTING SYSTEM
ENGINE ELECTRICAL16-25
MAGNETIC SWITCH RETURN TEST1. 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.
AK300652AB
<4G1>
S
BMWire
Battery Starter
motor
AKX01248
<4G6>
S
B M
Battery
Starter
motorWire
AF

Page 90 of 788
STARTING SYSTEM
ENGINE ELECTRICAL16-26
DISASSEMBLY AND REASSEMBLYM1162001200202
AK201881
14
1211
20
1
15161718191310 2
4
3
5
7
6
8
9
AG
Disassembly steps
1. Screw
<>2. Magnetic switch
3. Screw
4. Bolt
5. Rear bracket
6. Brush holder
7. Rear bearing
8. Armature
9. Yoke assembly
10. Packing A11. Packing B
12. Plate
13. Planetary gear
14. Lever
<> >>A<<15. Snap ring
<> >>A<<16. Stop ring
17. Overrunning clutch
18. Internal gear
19. Planetary gear shaft
20. Front bracketDisassembly steps (Continued)

Page 91 of 788
STARTING SYSTEM
ENGINE ELECTRICAL16-27
DISASSEMBLY SERVICE POINTS
<> MAGNETIC SWITCH REMOVAL
CAUTION
Do not clamp the yoke assembly with a vise.
Disconnect the lead from the M terminal of the
magnetic switch.
<> 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 M1162001300157
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
AK201882
B terminal
M terminal S terminal
AC
AK100883AC
Socket wrench
Stop ring
Pinion Gear
Overrunning
clutch
AK202791
Snap ring
pliersSnap ring
Pinion gear
Overrunning
clutch
AB
AK202911
Overrunning
clutchStop ring
Snap ring Stop ring
AB
AK202712

Page 92 of 788
STARTING SYSTEM
ENGINE ELECTRICAL16-28
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.
ARMATURE COIL
1. Check the armature coil for short circuit as
follows:
AK202715
AK202711
SegmentUndercut
Mica
AB
AK201187
AK202710
Free
Lock
AB
AK202846
Brush
height
AB

Page 93 of 788
STARTING SYSTEM
ENGINE ELECTRICAL16-29
2. Set the armature in a growler.
CAUTION
Clean the surface of the armature thoroughly
before performing the test.
3. While holding a thin strip of iron against the
armature in parallel with its axis, turn the armature
slowly. The armature is normal if the iron strip is
not attracted to the armature or it does not vibrate.
4. Check the insulation between commutator
segments and armature coils. The armature coils
are properly insulated if no continuity is present.
5. Check continuity between a segment and another.
There is no open circuit in the tested coil if there is
continuity.
MAGNETIC SWITCH
1. Coil open circuit test
•Check that there is continuity between the M
terminal and body A.
•If there is no continuity, replace the magnetic
switch.
2. Contact fusion check
•Check that there is no continuity between the B
terminal and M terminal.
•If there is continuity, replace the magnetic switch.
3. Switch contact check
•Push the indicated end of the magnetic switch
with a strong force to close the internal contacts.
Without releasing the switch end, check that
there is continuity between the B terminal and M
terminal.
•If there is no continuity, replace the magnetic
switch.
AK202733
Growler
AB
AK202734
AK202713
AK202891
A
M terminal
AB
AK202892
M terminal B terminal
AB
AK202893
M terminal B terminal
AB

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MITSUBISHI Owners Manuals