Starting System - Lancer Mitsubishi Lancer Evolution IX

GENERAL DESCRIPTION

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

On the other hand, 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 starter 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

1. For models equipped with M/T, the interlock switch contact is switched OFF when the clutch pedal is depressed. When the ignition switch is then switched 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.
2. For models equipped with A/T, when the ignition switch is switched to the "ST" position while the selector lever is at the "P" or "N" position, the contact (magnetic switch) of the starter is switched ON and the starter motor is 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 the transmission range switch. < A/T >
4. Check starter relay. < M/T >
5. Check the interlock switch. < M/T >

The starter motor doesn't stop

1. Check the starter (magnetic switch).

TROUBLESHOOTING GUIDE

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

1. STEP 1. Q: Is the battery in good condition? (Refer to , Chassis Electrical - Battery - On-vehicle Service - «BATTERY CHECK»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/antenna-systems/#chassis-electrical-lancer__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) .) Check the starter relay and interlock switch. < M/T > Check the transmission range switch. (Refer to «TRANSMISSION RANGE SWITCH CHECK»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/automatic-trans/#on-vehicle-service-diagnosis-with-20l__transmission-range-switch-check) .) < 2.0L ENGINE A/T >, (Refer to «ON-VEHICLE SERVICE»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/automatic-trans/#on-vehicle-service-diagnosis-with-24l) .) < 2.4L ENGINE A/T > 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 Starting System - Starter Motor - «INSPECTION»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/starter/#starting-system-lancer) .) YES : Excessive rotational resistance of the engine. NO : Replace the starter motor.

STARTER RELAY CHECK < M/T >

BATTERY VOLTAGE CONTINUITY TEST RESULTS

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<< A >> STARTER ASSEMBLY REMOVAL

Remove the starter assembly from above the vehicle.

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Remove the starter assembly from above the vehicle.

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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.

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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 body.
3. Manually slide out the overrunning clutch as far as the pinion stopper position.
4. If the pinion remains out, everything is operating properly. If the pinion returns, the hold-in circuit is open. Replace the magnetic switch.

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1. Place the starter motor in a bench-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 90 Amps

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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 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 >> ARMATURE AND BALL REMOVAL

<< B >> MAGNETIC SWITCH REMOVAL

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1. Press a long socket wrench to the stop ring. Then tap the socket wrench to remove the stop ring to the pinion gear side.
2. After removing the snap ring (by using snap-ring pliers), remove the stop ring and the overrunning clutch.

STARTER MOTOR PART CLEANING

1. Do not immerse parts in cleaning solvent. Immersing the yoke and field coil assembly and/or armature will damage insulation. Wipe these parts with a shop towel only.
2. Do not immerse the drive unit in cleaning solvent. The overrunning clutch is pre-lubricated at the factory and solvent will wash lubrication from the clutch.
3. The drive unit may be cleaned with a brush moistened with cleaning solvent and wiped dry with a shop towel.

>>A<< STOP RING AND SNAP RING INSTALLATION

Using a suitable pulling tool, pull the overrunning clutch stop ring over the snap ring.

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1. Place the armature on a pair of V-blocks, and check the deflection by using a dial gauge. Standard value: 0.05 mm (0.002 inch) Limit: 0.1 mm (0.004 inch)
2. Check the outer diameter of the commutator. Standard value: 29.4 mm (1.16 inch) Minimum limit: 28.8 mm (1.13 inch)
3. Check the depth of the undercut between segments. Standard value: 0.5 mm (0.02 inch) Minimum limit: 0.2 mm (0.008 inch)

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 (0.27 in)
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 that the armature coil is not grounded.
2. Place the armature in a growler.
3. Hold a thin steel blade parallel and just above the armature while slowly rotating in the growler. A shorted armature will cause a blade to vibrate and be attracted to the core. Replace the shorted armature.
4. Check the insulation between the armature coil cores and the commutator segments. They are normal if there is no continuity.
5. Check for continuity between the segments. The condition is normal if there is continuity.

See also:
• BATTERY CHECK
• INSPECTION
• TRANSMISSION RANGE SWITCH CHECK
• ON-VEHICLE SERVICE
• INSPECTION