Mitsubishi Lancer Evolution X. Manual - part 99

 

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Mitsubishi Lancer Evolution X. Manual - part 99

 

 

STARTING SYSTEM

TSB Revision

ENGINE ELECTRICAL

16-27

STARTER MOTOR ASSEMBLY

REMOVAL AND INSTALLATION

M1162001002260

Pre-removal operation
• Engine Room Under Cover Front A, B and Engine Room 

Under Cover Center Removal (Refer to GROUP 51, 

Under Cover 

P.51-15

).

• Air Cleaner Body Removal (Refer to GROUP 15, Air 

Cleane

P.15-11

).

• Charge Air Cooler Outlet Hose E Removal (Refer to 

GROUP 15, Charge Air Cooler 

P.15-11

).

Post-installation operation
• Charge Air Cooler Outlet Hose E Installation (Refer to 

GROUP 15, Charge Air Cooler 

P.15-11

).

• Air Cleaner Body Installation (Refer to GROUP 15, Air 

Cleaner 

P.15-11

).

• Engine Room Under Cover Front A, B and Engine Room 

Under Cover Center and Engine Room Side Cover (RH) 

Installation (Refer to GROUP 51, Under Cover 

P.51-15

).

AC706237

1

AC

2

36 ± 9 N·m
27 ± 6 ft-lb

11 ± 1 N·m
93 ± 13 in-lb

Removal steps 

1.

Starter connector and terminal 
connection

<<A>>

2.

Starter assembly

STARTING SYSTEM

TSB Revision

ENGINE ELECTRICAL

16-28

REMOVAL SERVICE POINT

.

<<A>> STARTER ASSEMBLY REMOVAL

Remove the starter assembly from the lower front of the 
engine.

INSPECTION

M1162001100829

.

PINION GAP ADJUSTMENT

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 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

B

M

S

Battery

Switch

Starter
motor

Wire

AF

AKX00198

Stopper

Pinion gap

Pinion

AC

AKX00199

AKX01243

B

M

S

Battery

Starter 
motor

Wire

AF

STARTING SYSTEM

TSB Revision

ENGINE ELECTRICAL

16-29

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 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

.

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

B

M

S

Battery

Starter 
motor

Wire

AF

AKX01247

S

M

B

Ammeter

Carbon-pile
rheostat

Battery

Starter
motor

Voltmeter

AF

A

V

AKX01249

B

M

S

Battery

Starter 
motor

Wire

AF

STARTING SYSTEM

TSB Revision

ENGINE ELECTRICAL

16-30

DISASSEMBLY AND ASSEMBLY

M1162001200611

AK704430 AB

2

16

17

18

19

15

13

12

20

4

14

11

1

5

6

8

7

9

10

3

6.1 ± 1.0 N·m
54 ± 8 in-lb

3.4 ± 1.0 N·m
30 ± 8 in-lb

5.8 ± 1.6 N·m
52 ± 13 in-lb

DISASSEMBLY STEPS 

1. Screw

<<

A>>

2. Magnetic switch
3. Screw
4. Bolt
5. Rear bracket
6. Brush holder
7. Rear bearing
8. Armature
9. Yoke assembly
10. Packing A

11. Packing B
12. Plate
13. Planetary gear
14. Lever

<<

B>> >>A

<< 15. Snap ring

<<

B>> >>A

<< 16. Stop ring

17. Overrunning clutch
18. Internal gear
19. Planetary gear shaft
20. Front bracket

DISASSEMBLY STEPS 

 

 

 

 

 

 

 

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