Mitsubishi Lancer. Manual - part 207

STARTING SYSTEM

ENGINE ELECTRICAL

16-20

STARTER MOTOR SPECIFICATIONS

Item

4G1

4G6

Type

Reduction drive with planetary 
gear

Reduction drive with planetary gear

Rated output kW/V

1.2/12

1.4/12

Number of pinion teeth

8

8

SERVICE SPECIFICATIONS

M1162000300068

Item

Standard value

Limit

Pinion gap mm

0.5 

− 2.0

−

Commutator run-out mm

−

0.05

Commutator diameter mm

29.4

28.8

Undercut depth mm

0.5

 0.2

STARTING SYSTEM

ENGINE ELECTRICAL

16-21

STARTER MOTOR ASSEMBLY

REMOVAL AND INSTALLATION <4G1>

M1162001000628

Pre-removal and Post-installation Operation
• Air Cleaner Assembly Removal and Installation (Refer to 

GROUP 15 

P.15-3

).

• Battery and Battery Tray Removal and Installation

AC303962 AB

1

1

2

3

5

6

7

4

30 ± 3 N·m

18 ± 3 N·m

12 ± 2 N·m

<M/T>

<A/T>

12 ± 2 N·m

Removal steps 

1.

Shift cable connection

<<

A

>>

2.

Shift cable and shift cable bracket 
assembly <M/T>

<<

B

>>

3.

Shift cable connection <A/T>

4.

Starter connector and terminal

5.

Harness bracket <M/T>

6.

Harness bracket <A/T>

<<

C

>>

7.

Starter assembly

REMOVAL SERVICE POINT
<<A>> SHIFT CABLE AND SHIFT CABLE 
BRACKET ASSEMBLY <M/T> REMOVAL

Remove the shift cable bracket installation bolt with 
the shift cable installed on the shift cable bracket, 
and remove the shift cable and shift cable bracket 
assembly from the transmission.

<<B>> SHIFT CABLE CONNECTION 
<A/T> REMOVAL

Disengage the transmission, and remove the shift 
cable assembly from the transmission.

<<C>> STARTER ASSEMBLY REMOVAL

Remove the starter assembly from above the vehi-
cle.

STARTING SYSTEM

ENGINE ELECTRICAL

16-22

REMOVAL AND INSTALLATION <4G6>

M1162001001278

Pre-removal and Post-installation Operation
• Air Cleaner Assembly Removal and Installation (Refer to 

GROUP 15 

P.15-3

).

• Under Cover Removal and Installation

AC304005

5

2

1

6

49 ± 9 N·m

18 ± 3 N·m

9.0 ± 2.0 N·m

30 ± 3 N·m

AB

4

3

12 ± 2 N·m

Removal steps 

1.

Starter cover

2.

Starter connector and terminal

3.

Clutch release cylinder connecting 
bolts <M/T>

4.

Clutch hose clamp <M/T>

<<

A

>>

5.

Starter assembly

6.

Starter cover bracket

REMOVAL SERVICE POINT
<<A>> STARTER ASSEMBLY REMOVAL

Remove the starter assembly from above the vehi-
cle.

STARTING SYSTEM

ENGINE ELECTRICAL

16-23

STARTER MOTOR ASSEMBLY INSPECTION

M1162001100205

PINION GAP ADJUSTMENT

AK300648 AB

<4G1>

Switch

S

M

Wire

Battery

Starter
motor

B

AKX01238

<4G6>

B

M

S

battery

Switch

Starter 
motor

Wire

AG

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 seconds) to prevent the coil from burning.
3. Set the switch to "ON", and the pinion will move 

out.

AKX00198

Stopper

Pinion gap

Pinion

AC

4. Check the pinion-to-stopper clearance (pinion 

gap) with a feeler gauge.

Standard value: 0.5 

− 2.0 mm

AKX00199

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

AK300649 AB

<4G1>

S

M

Wire

Battery

Starter
motor

B

AKX01242

<4G6>

S

B

M

Battery

Starter 
motor

Wire

AF

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.