Starting System - Lancer Evolution: Removal & Installation Mitsubishi Lancer X

<< A >> STARTER ASSEMBLY REMOVAL

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.

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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 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.

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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

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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 >> 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.

>> 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: 0.10 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 (0.01 inch)