Starter - Mitsubishi Mazda 626 GC

DESCRIPTION

Starter is a conventional 12-volt, 4-pole brush-type motor, with either direct or reduction gear drive. The starter-mounted solenoid shifts overrunning clutch and pinion into flywheel when starter is energized.

MITSUBISHI STARTER APPLICATION

No Load Tests

Connect starter in series with a 12-volt battery, a voltmeter and a 1000 amp ammeter. Compare readings with STARTER NO LOAD SPECIFICATIONS.

MITSUBISHI STARTER NO LOAD SPECIFICATIONS (1)

Load (Lock Torque) Test

Mount starter in a test stand to perform torque measurement test. Follow manufacturer's instructions for test stand operation. With voltage adjusted, ammeter reading and torque should be within specifications.

MITSUBISHI STARTER LOAD TEST SPECIFICATIONS (1)

SOLENOID TESTS

Note. Make tests with solenoid removed from starter or remove solenoid lead to starter before testing. Ensure solenoid plunger and sleeve are clean and dry before performing tests. Make tests in less than 10 seconds to prevent coil damage.

Scheme 1

1. Connect jumper between positive post of 12 volt battery and "S" terminal. Connect a second jumper to negative battery terminal and touch "M" (MT) terminal (and between terminal "S" and switch body). (Scheme 1) (Scheme 1): Connections for Conducting Solenoid Pull-In Test. Remove solenoid-to-starter lead before testing.
2. If pinion moves outward (or plunger is pulled-in), pull-in coil is good. If not, replace magnetic switch.

Scheme 2

1. Connect a jumper wire between the "M" (MT) terminal and solenoid case. Apply 8 volts to "S" terminal to pull in the plunger. (Scheme 2) Disconnect lead to "M" (MT) terminal. (Scheme 2): Connections for Conducting Solenoid Hold-In Test. Make tests in less than 10 seconds to avoid solenoid damage.
2. If pinion remains out (plunger is pulled-in), hold-in coil is good. If not, replace magnetic switch.

Scheme 3

1. Apply 12 volts between "M" (MT) terminal and the solenoid case. Pull pinion out and release it (push plunger into solenoid body by hand). (Scheme 3) (Scheme 3): Connections for Conducting Return Test. Connect battery to "M" terminal and solenoid case.
2. If the case is short-circuited, the pinion will remain out (plunger will be attracted). If nothing happens, solenoid is good.

REMOVAL & INSTALLATION

1. On all models, remove negative battery cable. If necessary raise vehice on hoist. Remove starter mounting bolts. Remove starter from vehicle.

DISASSEMBLY

Note. Procedures may vary slightly between conventional and reduction gear starters.

1. Loosen nut securing connecting plate-to-magnetic switch M" terminal. Remove screws securing magnetic switch and remove switch (solenoid) assembly. Remove through bolts and brush cover assembly. Tap yoke assembly loose with wooden mallet. Remove yoke, armature assembly and pinion shift lever.
2. Remove pinion stop ring from end of armature shaft by pushing stop ring to clutch side. Remove snap ring and overrunning clutch assembly from armature shaft.

CLEANING & INSPECTION

Clean all parts. Do not use grease dissolving solvent on overrunning clutch, armature assembly, solenoid assembly or field coils due to possible damage. Inspect all parts for damage or wear and replace as required.

Brushes & Springs

Check brush spring tension using a spring scale. Check brush contact surface condition and brush length. Check lead clip and wire connections and condition of brush holders. Replace as required. See BRUSH SPRING TENSION and MINUMUM BRUSH LENGTH charts.

BRUSH SPRING TENSION

MINIMUM BRUSH LENGTH

Armature

Check external condition of armature for scoring or other damage. Measure shaft runnout with dial indicator. Replace armature if shaft runnout exceeds .004" (.10 mm).

Commutator

1. Inspect commutator for roughness, grooves, burns or pitting. Sand lightly with 500 grit sandpaper if necessary. Check commutator for out-of-round and mica insulators undercut to a depth of .020-.031" (.50-.80 mm).
2. If necessary, commutator may be turned less than .04" 1.0 mm) from original size and mica undercut. Replace if excessively worn.

Field Coil

1. Check field coil continuity by connecting test probe of circuit tester or an ohmmeter to the field coil positive terminal and brush holder. If circuit is open, replace field coil.
2. Check for grounding of field coils by placing one probe of circuit tester on starter housing and other probe to field coil positive terminal. If little or no resistance, field coil is grounded and must be replaced.

Overrunning Clutch Assembly

1. Inspect pinion assembly and sleeve. Sleeve should slide freely on armature shaft and spline. If damage or resistance is noted, replace assembly.
2. Check pinion and flywheel teeth for excessive rubbing or damaged teeth. Replace as required.

Pinion Gear Clearance

1. The clearance between the pinion gear and pinion stopper collar should be .02-.08" (.51-2.03 mm) on Mitsubishi starters, when solenoid is engaged. Adjust as necessary by changing shims between solenoid and starter yoke.
2. On Mazda B2200 models, projection distance (starter housing-to-front face of gear) should be .67" (17 mm).

Pinion Case Bearing

Inspect bearing for wear and check side play. If clearance exceeds .008" (.20 mm), replace bearing. New bearing clearance should be .002-.004" (.05-.10 mm) for Mitsubishi starters.

Note. Ensure that bearing is installed so that end of bearing is flush with gear case end.

REASSEMBLY

To reassemble, reverse disassembly procedure. Fill rear case on reduction gear models with grease. Lightly oil pinion and all bearing surfaces.

Measuring Pinion Edge-to-Pinion Stopper Clearance. Scheme 4

Disassembled View of Typical Hitachi Reduction Gear Starter. Scheme 5

Disassembled View of Typical Mitsubishi Conventional Starter For B2200 Diesel Pickup. Scheme 6