Starting System - Lancer Evolution Mitsubishi Lancer Evolution IX

GENERAL DESCRIPTION

If the ignition switch is turned to the "START" position, current flows in the coil provided inside the magnetic switch, attracting the plunger. When the plunger is attracted, the lever connected to the plunger is actuated to engage the overrunning clutch with the ring gear.

At the same time, attracting the plunger will turn on the magnetic switch, allowing the "B" terminal and "M" terminal to conduct. Thus, current flows to engage the starter motor.

When the ignition switch is returned to the "ON" position after starting the engine, the overrunning clutch is disengaged from the ring gear.

An overrunning clutch is provided between the pinion and the armature shaft, to prevent damage to the starter.

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OPERATION

The interlock switch contact is switched OFF when the clutch pedal is depressed. When the ignition switch is then turned to the "ST" position, electricity flows to the starter relay and the starter motor, the contact (magnetic switch) of the starter is switched ON and the starter motor is activated.

Note. If the ignition switch is switched to the "ST" position without the clutch pedal being depressed, electricity flows to the starter relay (coil), the interlock switch (contacts) and to ground, with the result that the contacts of the starter relay are switched OFF, and because the power to the starter motor is thereby interrupted, the starter motor in not activated.

TROUBLESHOOTING HINTS

The starter motor does not operate at all.

1. Check the starter (coil).
2. Check for poor connection at the battery terminals and starter.
3. Check starter relay.
4. Check the interlock switch.

The starter motor doesn't stop.

1. Check the starter (magnetic switch).

TROUBLESHOOTING GUIDE

The starting system troubleshooting guide is shown in the following steps.

1. STEP 1. Q: Is the battery in good condition? (Refer to «BATTERY CHECK»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/antenna-systems/#chassis-electrical-lancer-evolution__battery-check) .) YES: Go to Step 2. NO: Charge or replace the battery.
2. STEP 2. Disconnect the starter motor "S" (solenoid) terminal connector. Using a jumper wire, apply battery positive voltage to the starter motor "S" (solenoid) terminal. Check the engine condition. OK: Turns normally Q: Does the starter motor operate normally? YES: Check the ignition switch (Refer to «INSPECTION»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/antenna-systems/#chassis-electrical-lancer-evolution__inspection) .) Check the starter relay and interlock switch. Check the line between the battery and starter motor "S" (solenoid) terminal. NO: Go to Step 3.
3. STEP 3. Check the cable between starter "B" (battery) terminal and battery positive terminal for connection and continuity. Q: Is the starter cable in good condition? YES: Go to Step 4. NO: Repair or replace the cable.
4. STEP 4. Check the connection and the continuity of the cable between the starter motor body and the negative battery terminal. Q: Is the ground cable in good condition? YES: Go to Step 5. NO: Repair or replace the cable.
5. STEP 5. Q: Is the starter motor in good condition? (Refer to «INSPECTION»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/starter/#starting-system-lancer-evolution) .) YES: Starter motor is normal. Check the excessive rotational resistance of the engine. NO: Replace the starter motor.

STARTER RELAY CHECK

STARTER RELAY REFERENCE CHART

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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 mm (0.02 - 0.07 inch)
5. If the pinion gap is out of specification, adjust by adding or removing gasket(s) between the magnetic switch and front bracket.

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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.

Scheme 39

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 operating properly. If the pinion moves in, the hold-in circuit is open. Replace the magnetic switch.

Scheme 40

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 95 Amps

Scheme 41

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 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.

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<< A >> MAGNETIC SWITCH REMOVAL

Disconnect the lead from the M terminal of the magnetic switch.

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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 packed in the overrunning clutch at the factory will be washed out. Wipe the drive unit with cloth if it requires cleaning.

>> A << STOP RING/SNAP RING INSTALLATION

Use a suitable puller to pull the stop ring until it gets over the snap ring.

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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
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.

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1. Make sure that the pinion cannot be turned counterclockwise, and can be turned clockwise freely.
2. Check the pinion for abnormal wear and damage.

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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.

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1. Check the armature coil for short circuit as follows
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.

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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.

See also:
• BATTERY CHECK
• INSPECTION
• INSPECTION