Mitsubishi Montero Sport (2004+). Manual - part 95

STARTING SYSTEM

TSB Revision

ENGINE ELECTRICAL

16-21

STARTING SYSTEM DIAGNOSIS

M1162000700301

TROUBLESHOOTING HINTS

The starter motor dose not operate at all.

WARNING

Battery posts, terminals and related accessories con-
tain lead and lead compounds. WASH HANDS AFTER 
HANDLING.

• 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.

WARNING

Battery posts, terminals and related accessories con-
tain lead and lead compounds. WASH HANDS AFTER 
HANDLING.

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

Chassis Electrical 

− Battery − On-vehicle Service − 

Battery Check 

P.54-5

.)

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 54A, 

Chassis Electrical 

− Ignition Switch − Ignition 

Switch Removal and Installation 

− Inspection 

P.54-74

.)

• Check the transmission range switch.(Refer to 

GROUP 23A, Automatic Transmission 

− 

On-vehicle Service 

− Essential Service − 

Transmission Range Switch Continuity Check 

P.23A-435

.)

• Check the line between the battery and starter 

motor S (solenoid) terminal.

NO :  Go to Step 3.

STARTING SYSTEM

TSB Revision

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 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 Assembly − Inspection 

P.16-17

.)

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

ON-VEHICLE SERVICE

STARTER RELAY CHECK

M1162001400217

BATTERY 
VOLTAGE

TESTER 
CONNECTION

CONTINUITY TEST 
RESULTS

Not applied

2 

− 4

Open circuit

• Connect terminal 

3 to the positive 
battery terminal

• Connect terminal 

1 to the negative 
battery terminal

2 

− 4

Less than 2 ohms

AC390278

4

3

2

1

1

3

2

4

AB

STARTER RELAY

STARTING SYSTEM

TSB Revision

ENGINE ELECTRICAL

16-23

STARTER MOTOR ASSEMBLY

REMOVAL AND INSTALLATION

M1162001000714

INSPECTION

M1162001100142

.

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.

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

42, Under Cover 

P.42-207

).

• Actuator Assembly Removal and Installation (Refer to 

GROUP 26, Differential Carrier 

P.26-40

).

AC004507AB

26 - 33 N·m
20 - 25 ft-lb

1

2

3

4

REMOVAL STEPS

1. STARTER COVER
2. STARTER CONNECTOR

3. BATTERY CABLE
4. STARTER ASSEMBLY

REMOVAL STEPS (Continued)

AKX00197

SWITCH

S

B

M

WIRE

STARTER
MOTOR

BATTERY

AB

STARTING SYSTEM

TSB Revision

ENGINE ELECTRICAL

16-24

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.

.

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.

.

AKX00198

STOPPER

PINION GAP

PINION

AB

AKX00199

AKX00200

S

B

M

WIRE

STARTER
MOTOR

BATTERY

AB

AKX00201

S

B

M

WIRE

STARTER
MOTOR

BATTERY

AB