Starters - Except Evolution & Sportback Mitsubishi Lancer Evolution VIII

DESCRIPTION & OPERATION

If the ignition switch is turned to START position, current flows in the coil provided inside magnetic switch, attracting the plunger. When plunger is attracted, the lever connected to plunger is actuated to engage starter clutch. On the other hand, attracting plunger will turn on magnetic switch, allowing "B" terminal and "M" terminal to conduct. Thus, current flows to engage starter motor. When ignition switch is returned to ON position after starting engine, starter clutch is disengaged from ring gear.

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

For models equipped with M/T, clutch pedal position switch contact is switched OFF when clutch pedal is depressed. When ignition switch is switch to START position, electricity flows to starter relay and starter motor, contact (magnetic switch) of the starter is switched ON and starter motor is activated. If the ignition switch is switched to START position without clutch pedal being depressed, electricity flows to starter relay (coil), clutch pedal position switch (contacts) and to ground, with result that contacts of starter relay are switched OFF and because power to starter motor is thereby interrupted, starter motor will not operate.

For models, equipped with A/T, when the ignition switch is switched to the START 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.

PINION GAP

1. Disconnect the field coil wire from the "M" terminal of magnetic switch. (Scheme 22)or (Scheme 23).
2. Connect a 12V battery between "S" terminal and "M" terminal.
3. Set switch to ON and pinion will move out.
4. Check the pinion to stopper clearance (pinion gap) with a feeler gauge. (Scheme 24)
5. If the pinion gap is out of specification, adjust by adding or removing gasket(s) between the magnetic switch and front bracket.

Scheme 22

Scheme 23

Scheme 24

TROUBLE SHOOTING

STARTER MOTOR DOES NOT OPERATE

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

STARTER MOTOR DOES NOT STOP

Check magnetic switch.

ON-VEHICLE TESTING

1. Is the battery in good condition? If Yes, go to the next step. If No, then charge or replace battery.
2. Disconnect the starter motor "S" (solenoid) terminal connector. Using a jumper wire, apply battery positive voltage to starter motor "S" (solenoid) terminal. Does starter motor operate normally? If Yes, then check ignition switch, starter relay, interlock switch, transmission range switch and the line between the battery and starter motor "S" (solenoid) terminal. If No, then go to the next step.
3. Check if the cable between starter "B" (battery) terminal and battery positive terminal for connection and continuity. Is the starter cable in good condition? If Yes, then go to the next step. If No, then repair or replace the cable.
4. Check the connection and continuity of the cable between starter motor body and the negative battery terminal. Is the ground cable in good condition? If Yes, then go to the next step. If No, then repair or replace cable.
5. Is the starter motor in good condition? If Yes, problem is excessive rotational resistance of the engine. If No, then replace the starter motor.

STARTER RELAY CHECK

For starter relay location (Scheme 25)

Scheme 25

MAGNETIC SWITCH PULL-IN TEST

1. Disconnect field coil wire from "M" terminal of the magnetic switch. (Scheme 26)or (Scheme 27).
2. Connect a 12-volt battery between "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 26

Scheme 27

MAGNETIC SWITCH HOLD IN TEST

1. Disconnect the field coil wire from "M" terminal of the magnetic switch. (Scheme 28)or (Scheme 29).
2. Connect 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 pinion moves in, hold-in circuit is open. Replace the magnetic switch.

Scheme 28

Scheme 29

MAGNETIC SWITCH RETURN TEST

1. Disconnect the field coil wire from the "M" terminal of the magnetic switch. (Scheme 30)or (Scheme 31).
2. Connect a 12-volt battery between the "M" terminal and body.
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.

Scheme 30

Scheme 31

FREE RUNNING TEST

1. Place the starter motor in a vise equipped with soft jaws and connect a fully-charged 12-volt battery to starter motor.
2. Connect a test ammeter (100-ampere scale) and carbon pile rheostat in series between the positive battery terminal and starter motor terminal. (Scheme 32)or (Scheme 33).
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 11V.
7. Confirm that the maximum amperage is 95 amps, and that the starter motor turns smoothly and freely.

Scheme 32

Scheme 33

COMMUTATOR CHECK

1. Place the armature on a pair of V-blocks and check the runout by using a dial gauge. See «STARTER SPECIFICATIONS»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/starter/#starters-except-evolution-sportback__starter-specifications) .
2. Check the outer diameter of the commutator. See «STARTER SPECIFICATIONS»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/starter/#starters-except-evolution-sportback__starter-specifications) .
3. Check the depth of the undercut between segments. See «STARTER SPECIFICATIONS»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/starter/#starters-except-evolution-sportback__starter-specifications) .
4. Replace commutator, if runout, diameter or undercut depth is not within specification.

BRUSH HOLDER CHECK

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.

BRUSH CHECK

1. Check the brush for roughness of the surface that contacts the commutator and check the brush length. Replace the brush holder if this measurement exceeds the limit. The minimum limit is .28" (7.0 mm).
2. In the case contacting surface has been corrected or the brush has been replaced, correct the contacting surface winding sandpaper around the commutator.

OVERRUNNING CLUTCH

1. Make sure that the pinion can not be turned counterclockwise, and can be turned clockwise freely. (Scheme 34)
2. Check the pinion for abnormal wear and damage.

Scheme 34

ARMATURE CHECK

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. (Scheme 35) Replace the shorted armature.
4. Check the insulation between the armature coil cores and the commutator segments. (Scheme 36) They are normal if there is no continuity.
5. Check for continuity between the segments. (Scheme 37) The condition is normal if there is continuity.

Scheme 35

Scheme 36

Scheme 37

REMOVAL & INSTALLATION

Note. Information is not available from manufacturer.

OVERHAUL

Note. To assist in overhaul, use illustrations. (Scheme 38)or (Scheme 39).

Scheme 38

Scheme 39

Disassembly (Armature & Ball)

Disassembly (Stop & Snap Ring)

1. Press a long socket wrench of appropriate size to the stop ring. Then tap the socket wrench to move the stop ring to ward the pinion gear. (Scheme 40)
2. After removing the snap ring, slide the stop ring and the overrunning clutch off the pinion shaft. (Scheme 41)

Scheme 40

Scheme 41

Cleaning

Reassembly (Stop & Snap Ring)

Using a suitable pulling tool, pull the overrunning clutch stop ring over the snap ring. (Scheme 42)

Scheme 42

STARTER SPECIFICATIONS

STARTER SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

WIRING DIAGRAMS

For starting system wiring diagram, see STARTING/CHARGING in appropriate SYSTEM WIRING DIAGRAMS article in ELECTRICAL.

See also:
• STARTER SPECIFICATIONS