Mitsubishi Galant 9G. Manual - part 358

STARTING SYSTEM

TSB Revision

ENGINE ELECTRICAL

16-28

REMOVAL AND INSTALLATION <3.8L ENGINE>

M1162001000651

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

P.51-11

). 

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

TSB Revision

ENGINE ELECTRICAL

16-29

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.

.

AKX01238

<2.4L ENGINE>

B

M

S

BATTERY

SWITCH

STARTER 
MOTOR

WIRE

AC

AKX01239

<3.8L ENGINE>

B

M

S

BATTERY

SWITCH

STARTER 
MOTOR

WIRE

AE

AKX00198

STOPPER

PINION GAP

PINION

AB

AKX00199

STARTING SYSTEM

TSB Revision

ENGINE ELECTRICAL

16-30

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.

.

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.

.

AKX01242

<2.4L ENGINE>

S

B

M

BATTERY

STARTER 
MOTOR

WIRE

AB

AKX01243

<3.8L ENGINE>

B

M

S

BATTERY

STARTER 
MOTOR

WIRE

AE

AKX01244

<2.4L ENGINE>

S

B

M

BATTERY

STARTER 
MOTOR

WIRE

AB

AKX01245

<3.8L ENGINE>

B

M

S

BATTERY

STARTER 
MOTOR

WIRE

AE

STARTING SYSTEM

TSB Revision

ENGINE ELECTRICAL

16-31

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 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.

AKX01246

<2.4L ENGINE>

S

M

B

AMMETER

CARBON-PILE 
RHEOSTAT

BATTERY

STARTER 
MOTOR

VOLTMETER

AB

A

V

AKX01247

<3.8L ENGINE>

B

M

S

CARBON-PILE 
RHEOSTAT

AMMETER

BATTERY

STARTER 
MOTOR

VOLTMETER

AE

A

V

AKX01248

<2.4L ENGINE>

S

B

M

BATTERY

STARTER 
MOTOR

WIRE

AB

AKX01249

<3.8L ENGINE>

B

M

S

BATTERY

STARTER 
MOTOR

WIRE

AE