Mitsubishi Montero (2002-2004). Manual - part 1086

CHARGING SYSTEM

TSB Revision

ENGINE ELECTRICAL

16-17

2. Check the continuity between the negative rectifier and the 

stator coil lead connection terminal with a tester. If there is 
continuity between the terminals, the diode is grounded, so 
replace the rectifier.

3. Check the continuity of the three diodes by connecting an 

ohmmeter to both ends of each diode. If there is continuity 
between the directions, or if there is no continuity, the diode 
is damaged, so replace the rectifier.

.

BRUSH CHECK
1. Replace the brush if the brush protrusion length shown in 

the illustration is below the minimum limit value.

Minimum limit: 2 mm (0.08 inch)

2. The brush can be removed by unsoldering the brush lead 

wire.

3. When installing a new brush, push the brush in to the brush 

holder, and solder the lead wire.

AKX00365

AKX00366

AKX00367AB

PROTRUSION
LENGTH

AKX00368

SOLDERED

AB

STARTING SYSTEM

TSB Revision

ENGINE ELECTRICAL

16-18

STARTING SYSTEM

GENERAL DESCRIPTION

M1162000100149

If the ignition switch is turned to the "START" posi-
tion, current flows in the coil provided inside mag-
netic switch, attracting the plunger. When the plunger 
is attracted, the lever connected to the plunger is 
actuated to engage the starter clutch.
On the other hand, attracting the plunger will turn on 
the magnetic switch, allowing the "B" terminal and 
"M" terminal to conduct. Thus, current flows to 
engage the starter motor.

When the ignition switch is returned to the "ON" posi-
tion after starting the engine, the starter clutch is dis-
engaged from the ring gear.
An overrunning clutch is provided between the pinion 
and the armature shaft, to prevent damage to the 
starter.

OPERATION

• For models equipped with A/T, when the ignition 

switch is switched to the "ST" position while the 
selector lever is at the "P" or "N" position, the 
contact (magnetic switch) of the starter is 
switched ON and the starter motor is activated.

AKX00196

PULL-IN COIL

HOLDING
COIL

PLUNGER

LEVER

PINION SHAFT

OVERRUNNING
CLUTCH

YOKE

BRUSH

ARMATURE

IGNITION
SWITCH

BATTERY

+

–

AB

STARTING SYSTEM

TSB Revision

ENGINE ELECTRICAL

16-19

STARTING SYSTEM DIAGNOSIS

M1162000700204

TROUBLESHOOTING HINTS

The starter motor dose not operate at all.

• Check the starter (coil).

• Check for poor contact at the battery terminals and 

starter.

• Check the transmission range switch.

The starter motor doesn’t stop.

• Check the starter (magnetic switch).

TROUBLESHOOTING GUIDE

The starting system troubleshooting guide is shown in the fol-
lowing chart.

STEP 1.
Q: Is the battery in good condition? (Refer to GROUP 54A, 

Battery 

− Battery check 

P.54A-4

.)

YES : Go to Step 2.
NO :  Charge or replace the battery.

STEP 2.

• Disconnect the starter motor S (solenoid) terminal connec-

tor.

• Using a jumper wire, apply battery voltage to the starter 

motor S (solenoid) terminal.

• Check the engine condition.

OK: Turns normally

Q: Does the starter motor operate normally?

YES : 

• Check the ignition switch. (Refer to GROUP 54, 

Ignition switch 

P.54A-31

.)

• Check the starter relay

• Check the transmission range switch.(Refer to 

GROUP 23A, Automatic Transaxle On-vehicle 
Service 

P.23Aa-20

.)

• Check the line between the battery and starter 

motor S (solenoid) terminal.

NO :  Go to Step 3.

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

STARTING SYSTEM

TSB Revision

ENGINE ELECTRICAL

16-20

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 line 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 − Inspection 

P.16-21

.)

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

STARTER MOTOR ASSEMBLY

REMOVAL AND INSTALLATION

M1162001000435

Pre-removal and Post-installation Operation
• Under Cover Removal and Installation

ACX02077AB

1

2

3

4

30 ± 3 N·m
22 ± 2 ft-lb

REMOVAL STEPS

1.

STARTER COVER

2.

STARTER CONNECTOR

3.

BATTERY CABLE

4.

STARTER ASSEMBLY

REMOVAL STEPS (Continued)