Mitsubishi 380. Manual - part 250

STARTING SYSTEM

ENGINE ELECTRICAL

16-22

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.

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 wire in good condition?

YES : Go to Step 5.
NO :  Repair or replace the cable.

STEP 5.

Q: Is the starter motor in good condition? (Refer to Starting 

System 

− Starter Motor Assembly − Inspection 

P.16-17

.)

YES : Excessive rotational resistance of the engine.
NO :  Replace the starter motor.

STARTING SYSTEM

ENGINE ELECTRICAL

16-23

STARTER MOTOR ASSEMBLY

REMOVAL AND INSTALLATION 

M1162001000651

Pre-removal and Post-installation Operation
Under Cover Removal and Installation (Refer to GROUP 51, 
Under Cover 

P.51-13

). 

AC205798

4.9 ± 1.0 N·m
44 ± 8 in-lb

4.9 ± 1.0 N·m
44 ± 8 in-lb

30 ± 3 N·m
23 ± 2 ft-lb

30 ± 3 N·m
23 ± 2 ft-lb

1

2

3

AB

12 ± 2 N·m
102 ± 22 in-lb

REMOVAL STEPS

1.

STARTER CONNECTOR AND 
TERMINAL

2.

STARTER COVER

<<A>>

3.

STARTER ASSEMBLY

REMOVAL STEPS (Continued)

STARTING SYSTEM

ENGINE ELECTRICAL

16-24

REMOVAL SERVICE POINT

.

<<A>> STARTER ASSEMBLY REMOVAL

Remove the starter assembly from under the vehicle.

INSPECTION

M1162001100197

.

PINION GAP ADJUSTMENT

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 sec-
onds) 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.

.

MAGNETIC SWITCH PULL-IN TEST

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 sec-
onds) 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.

AKX01239

<3.8L ENGINE>

B

M

S

BATTERY

SWITCH

STARTER 

MOTOR

WIRE

AE

AKX00198

STOPPER

PINION GAP

PINION

AB

AKX00199

AKX01243

<3.8L ENGINE>

B

M

S

BATTERY

STARTER 

MOTOR

WIRE

AE

STARTING SYSTEM

ENGINE ELECTRICAL

16-25

.

MAGNETIC SWITCH HOLD-IN TEST

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 sec-
onds) 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.

.

FREE RUNNING TEST

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 the rheostat 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 

on 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

.

MAGNETIC SWITCH RETURN TEST

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 sec-
onds) 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.

AKX01245

<3.8L ENGINE>

B

M

S

BATTERY

STARTER 

MOTOR

WIRE

AE

AKX01247

<3.8L ENGINE>

B

M

S

CARBON-PILE 

RHEOSTAT

AMMETER

BATTERY

STARTER 

MOTOR

VOLTMETER

AE

A

V

AKX01249

<3.8L ENGINE>

B

M

S

BATTERY

STARTER 

MOTOR

WIRE

AE