MITSUBISHI MONTERO 1998 Service Manual

STARTER
1998 Mitsubishi Montero
1998 STARTING & CHARGING SYSTEMS
Mitsubishi - Starters
Diamante, Eclipse, Galant, Mirage, Montero, Montero Sport,
3000GT
DESCRIPTION & OPERATION
Starter is a conventional 12-volt, 4-pole brush-type motor,
with direct or gear reduction drive. Starter-mounted solenoid shifts
overrunning clutch and pinion into flywheel when starter is energized.
TROUBLE SHOOTING
NOTE: See TROUBLE SHOOTING article in the GENERAL INFORMATION
section.
ON-VEHICLE TESTING
TROUBLE SHOOTING
1) If starter motor does not operate at all:
* Check starter coil.
* Check electrical connections.
* Check clutch pedal position switch (M/T).
* Check starter relay (M/T).
* Check park/neutral position switch (A/T).
2) If starter motor does not stop, check starter magnetic
switch solenoid.
STARTER RELAY
Diamante, Galant & Montero
1) Remove starter relay. See STARTER RELAY LOCATIONS table.
With no power supplied to any relay, continuity should exist between
relay terminals No. 1 and 2. See WIRING DIAGRAMS.
2) Connect a jumper wire from positive battery terminal to
relay terminal No. 1 and another jumper wire from negative battery
terminal to relay terminal No. 2. Continuity should exist between
relay terminals No. 3 and 4. Replace relay as necessary.
Eclipse (A/T With Theft Alarm)
1) Remove starter relay. See STARTER RELAY LOCATIONS table.
With no power supplied to any relay, continuity should exist between
relay terminals No. 1 and 2. See WIRING DIAGRAMS.
2) Connect a jumper wire from positive battery terminal to
relay terminal No. 1 and another jumper wire from negative battery
terminal to relay terminal No. 2. Continuity should exist between
relay terminals No. 3 and 4. Replace relay as necessary.
Eclipse (A/T Without Theft Alarm)
1) Remove starter relay. See STARTER RELAY LOCATIONS table.
With no power supplied to any relay, continuity should exist between
relay terminals No. 1 and 3. See WIRING DIAGRAMS.
2) Connect a jumper wire from positive battery terminal to
relay terminal No. 1 and another jumper wire from negative battery

terminal to relay terminal No. 3. Continuity should exist between
relay terminals No. 4 and 5. Replace relay as necessary.
Eclipse (M/T With Theft Alarm)
1) Remove starter relay. See STARTER RELAY LOCATIONS table.
With no power supplied to any relay, continuity should exist between
relay terminals No. 1 and 3. See WIRING DIAGRAMS.
2) Connect a jumper wire from positive battery terminal to
relay terminal No. 3 and another jumper wire from negative battery
terminal to relay terminal No. 1. Continuity should exist between
relay terminals No. 2 and 5. Replace relay as necessary.
Eclipse (M/T Without Theft Alarm)
1) Remove starter relay. See STARTER RELAY LOCATIONS table.
With no power supplied to any relay, continuity should exist between
relay terminals No. 1 and 2. See WIRING DIAGRAMS.
2) Connect a jumper wire from positive battery terminal to
relay terminal No. 1 and another jumper wire from negative battery
terminal to relay terminal No. 2. Continuity should exist between
relay terminals No. 3 and 4. Replace relay as necessary.
Mirage
1) Remove starter relay. See STARTER RELAY LOCATIONS table.
With no power supplied to any relay, continuity should exist between
relay terminals No. 1 and 3. See WIRING DIAGRAMS.
2) Connect a jumper wire from positive battery terminal to
relay terminal No. 3 and another jumper wire from negative battery
terminal to relay terminal No. 1. Continuity should exist between
relay terminals No. 2 and 4. Replace relay as necessary.
Montero Sport With A/T
1) Remove starter relay. See STARTER RELAY LOCATIONS table.
With no power supplied to any relay, continuity should exist between
relay terminals No. 1 and 3. See WIRING DIAGRAMS.
2) Connect a jumper wire from positive battery terminal to
relay terminal No. 3 and another jumper wire from negative battery
terminal to relay terminal No. 1. Continuity should exist between
relay terminals No. 2 and 5. Replace relay as necessary.
Montero Sport With M/T
1) Remove starter relay. See STARTER RELAY LOCATIONS table.
With no power supplied to any relay, continuity should exist between
relay terminals No. 1 and 3. See WIRING DIAGRAMS.
2) Connect a jumper wire from positive battery terminal to
relay terminal No. 1 and another jumper wire from negative battery
terminal to relay terminal No. 3. Continuity should exist between
relay terminals No. 2 and 4. Replace relay as necessary.
3000GT
1) Remove starter relay. See STARTER RELAY LOCATIONS table.
With no power supplied to any relay, continuity should exist between
relay terminals No. 1 and 2 and between relay terminals No. 3 and 4.
See Fig. 1 .
2) Connect a jumper wire from positive battery terminal to
relay terminal No. 1 and another jumper wire from negative battery
terminal to relay terminal No. 2. Continuity should exist between
relay terminals No. 3 and 5. See Fig. 1. Replace relay as necessary.
STARTER RELAY LOCATIONS TABLE









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Application Location
Diamante ............. At Left Front Fender, Inside Fuse/Relay Block

Eclipse
Without Theft Alarm ........................ Behind Center Of Dash
With Theft Alarm .... Under Left Of Instrument Panel, On Relay Box
Galant ................................... Inside Right Front Fender
Mirage .......................... In Left Underhood Fuse/Relay Block
Montero ...................................... Behind Center Of Dash
Montero Sport ................... In Left Underhood Fuse/Relay Block
3000GT ......................... In Right Underhood Fuse/Relay Block









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Fig. 1: Identifying Starter Relay Connector Terminals (3000GT)
Courtesy of Chrysler Corp.
BENCH TESTING
* PLEASE READ THIS FIRST *
CAUTION: Perform tests in less than 10 seconds to prevent damage to
coil.
NO-LOAD TEST
1) Install starter in soft-jawed vise. Connect starter in
series with a fully-charged 12-volt battery. Connect a 100-amp ammeter
and carbon pile rheostat in series with positive battery post and
starter motor terminal. See Fig. 2.
2) Install voltmeter across starter motor. Adjust carbon pile
rheostat to full resistance. Connect cable from starter motor body to
negative battery terminal. Adjust carbon pile rheostat to proper test
voltage. Ensure maximum amperage is as specified and starter rotates

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.

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.

Fig. 4: Measuring Pinion Gap
Courtesy of Mitsubishi Motor Sales of America
PINION TEST
While holding pinion housing, rotate pinion. Pinion should
rotate smoothly in clockwise direction only. Inspect pinion and ring
gear for wear or burrs. If pinion does not rotate as specified or
damage is found, replace pinion.

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

Fig. 6: Exploded View Of Gear Reduction Starter (Typical)
Courtesy of Mitsubishi Motor Sales of America
STARTER SPECIFICATIONS

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

Fig. 7: Starting System Wiring Diagram (Diamante)