Starting System - Except Lancer Evolution Mitsubishi Lancer Evolution X

GENERAL INFORMATION

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.

Scheme 1

OPERATION

For models equipped with CVT and TC-SST, when the ignition switch is turned 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.

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

SERVICE SPECIFICATIONS

SERVICE SPECIFICATIONS

TROUBLESHOOTING HINTS

The starter motor does not operate at all.

1. Check the starter (coil).
2. Check for poor contact at the battery terminals and starter.
3. Check the transmission range 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/x-2007-2016/remont/body-electrical/#battery-except-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/x-2007-2016/remont/ignition-switchsteering-lock/#ignition-switch-except-lancer-evolution) .) Check the starter relay system (Refer to «ST SYSTEM AND STARTER RELAY SYSTEM»(/mitsubishi/lancer-evolution/x-2007-2016/remont/testing-diagnostics/#multiport-fuel-injection-mfi-20l-non-turbo-except-lancer-evolution) < M/T > or «INSPECTION PROCEDURE 26: IGNITION SWITCH-ST SYSTEM AND STARTER RELAY SYSTEM < CVT >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/testing-diagnostics/#multiport-fuel-injection-mfi-20l-non-turbo-except-lancer-evolution) < CVT > for 2.0L. Refer to «ST SYSTEM AND STARTER RELAY SYSTEM»(/mitsubishi/lancer-evolution/x-2007-2016/remont/testing-diagnostics/#multiport-fuel-injection-mfi-20l-turbo-except-lancer-evolution) for 2.0L Turbo. Refer to «ST SYSTEM AND STARTER RELAY SYSTEM»(/mitsubishi/lancer-evolution/x-2007-2016/remont/testing-diagnostics/#multiport-fuel-injection-mfi-24l-except-lancer-evolution) < M/T > or «INSPECTION PROCEDURE 26: IGNITION SWITCH-ST SYSTEM AND STARTER RELAY SYSTEM < CVT >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/testing-diagnostics/#multiport-fuel-injection-mfi-24l-except-lancer-evolution) < CVT >) for 2.4L. Check the transmission range switch. (Refer to «TRANSMISSION RANGE SWITCH CONTINUITY CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/automatic-trans/#continuously-variable-transaxle-on-vehicle-service-except-lancer-evolution__transmission-range-switch-continuity-check) .) < CVT > Check the shift lever position. (Refer to «SHIFT LEVER OPERATION CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/automatic-trans/#twin-clutch-sportronic-shift-transmission-tc-sst-on-vehicle-service-except-lancer-evolution) .) < TC-SST > 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 line 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/x-2007-2016/remont/starter/#starting-system-except-lancer-evolution) .) YES: Excessive rotational resistance of the engine. NO: Replace the starter motor.

STARTER RELAY CHECK

STARTER RELAY CONTINUITY CHART

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<< A >> STARTER CONNECTOR AND TERMINAL/STARTER ASSEMBLY REMOVAL

1. Slide the starter assembly, and remove the starter connector and terminal.
2. Remove the starter assembly from the lower front of the engine.

Scheme 4

1. Slide the starter assembly, and remove the starter connector and terminal.
2. Remove the starter assembly from the lower front of the engine.

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1. Disconnect the lead 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.

Scheme 8

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 9

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 10

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 90 Amps

Scheme 11

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.

Scheme 12

<< 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 having been 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. 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.

Scheme 22

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
• ST SYSTEM AND STARTER RELAY SYSTEM
• ST SYSTEM AND STARTER RELAY SYSTEM
• ST SYSTEM AND STARTER RELAY SYSTEM
• TRANSMISSION RANGE SWITCH CONTINUITY CHECK
• SHIFT LEVER OPERATION CHECK
• INSPECTION