Mitsubishi Outlander (2003+). Manual - part 139

STARTING SYSTEM

ENGINE ELECTRICAL

16-21

STARTER MOTOR SPECIFICATIONS

SERVICE SPECIFICATIONS

M1162000300079

Item

Specification

Type

Reduction drive with planetary gear

Rated output kW/V

1.4/12

Number of pinion teeth

8

Item

Standard value

Limit

Pinion gap mm

0.5 

−

 2.0

−

Commutator run-out mm

0.05

0.1

Commutator diameter mm

29.4

28.8

Undercut depth mm

0.5

 0.2

STARTING SYSTEM

ENGINE ELECTRICAL

16-22

STARTER MOTOR ASSEMBLY

REMOVAL AND INSTALLATION <4G63>

M1162001000725

REMOVAL SERVICE POINT

<<A>> STARTER ASSEMBLY REMOVAL
Remove the starter assembly from above the 
vehicle.

Pre-removal and Post-installation Operation

•

Resonator and Air Intake Duct Removal and Installation 

(Refer to GROUP 15, Air Cleaner 

P.15-3

).

•

Under Cover Removal and Installation (Refer to GROUP 

51, Under Cover 

P.51-19

).

AC301550

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

Removal steps

1.

Starter cover

2.

Starter connector

3.

Clutch release cylinder connecting 
bolts

4.

Clutch hose clamp

<<A>>

5.

Starter assembly

6.

Starter cover bracket

STARTING SYSTEM

ENGINE ELECTRICAL

16-23

REMOVAL AND INSTALLATION <4G69>

M1162001000639

REMOVAL SERVICE POINT

<<A>> STARTER ASSEMBLY REMOVAL
Remove the starter assembly from above the 
vehicle.

Pre-removal and Post-installation Operation

•

Air Duct Removal and Installation (Refer to GROUP 15, 

Air Cleaner 

P.15-4

).

•

Exhaust Manifold Heat Protector Removal and Installation 

(Refer to GROUP 15, Exhaust Manifold 

P.15-11

).

AC305106

1

2

3

4

5

6

12 ± 2 N·m

9.0 ± 2.0 N·m

30 ± 3 N·m

AC

49 ± 9 N·m

Removal steps

1.

Starter cover

2.

Harness clamp

3.

Starter connector

4.

Starter terminal

<<A>>

5.

Starter assembly

6.

Starter cover bracket

STARTING SYSTEM

ENGINE ELECTRICAL

16-24

STARTER MOTOR ASSEMBLY INSPECTION

M1162001100227

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 seconds) 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

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 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.

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 seconds) 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 in order. If 

the pinion moves in, the hold-in circuit is open. 
Replace the magnetic switch.

AKX01238

B

M

S

battery

Switch

Starter 
motor

Wire

AF

AKX00198

Stopper

Pinion gap

Pinion

AC

AKX00199

AKX01242

S

B

M

Battery

Starter 
motor

Wire

AE

AKX01244

S

B

M

Battery

Starter 
motor

Wire

AE