Mitsubishi Outlander (2003+). Manual - part 140

STARTING SYSTEM

ENGINE ELECTRICAL

16-25

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 95 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 seconds) 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

S

M

B

Ammeter

Carbon-pile
rheostat

Battery

Starter
motor

Voltmeter

AE

A

V

AKX01248

S

B

M

Battery

Starter 
motor

Wire

AE

STARTING SYSTEM

ENGINE ELECTRICAL

16-26

DISASSEMBLY AND REASSEMBLY

M1162001200224

AK304532

2

17

18

19

20

16

14

13

21

3

15

11

12

1

4

6

8

7

9

10

5

5.8 ± 1.6 N·m

5.8 ± 1.6 N·m

3.4 ± 1.0 N·m

AB

Disassembly steps

1. Screw

<<A>>

2. Magnetic switch
3. Screw
4. Bolt
5. Rear bracket
6. Brush holder
7. Rear bearing
8. Armature
9. Yoke assembly
10. Ball
11. Packing A

12. Packing B
13. Plate
14. Planetary gear
15. Lever

<<B>> >>A<<

16. Snap ring

<<B>> >>A<<

17. Stop ring
18. Overrunning clutch
19. Internal gear
20. Planetary gear shaft
21. Front bracket

Disassembly steps (Continued)

STARTING SYSTEM

ENGINE ELECTRICAL

16-27

DISASSEMBLY SERVICE POINTS

<<A>> MAGNETIC SWITCH REMOVAL

CAUTION

Do not clamp the yoke assembly with a vise.
Disconnect the lead from the M terminal of the 
magnetic switch.

<<B>> SNAP RING/STOP RING REMOVAL

1. Apply a long socket wrench of an appropriate size 

to the stop ring and strike the wrench to drive out 
the stop ring toward the pinion gear side.

2. Remove the snap ring with snap ring pliers, then 

remove the stop ring and overrunning clutch.

STARTER MOTOR PARTS CLEANING

Never clean in a solvent such starter motor parts as 

the magnetic switch, brush holder, and armature. 
If they are soaked in a solvent, their insulation 
could be impaired. When these parts require 
cleaning, wipe off contamination with cloth.

1. Never soak the drive unit in a solvent. If it is 

washed in a solvent, the grease having been 
packed in the overrunning clutch at the factory will 
be washed out. Wipe the drive unit with cloth if it 
requires cleaning.

REASSEMBLY SERVICE POINTS

>>A<< STOP RING/SNAP RING INSTALLATION

Use a suitable puller to pull the stop ring until it gets 
over the snap ring.

INSPECTION 

M1162001300179

COMMUTATOR

1. Support the armature with a pair of V block and 

turn it to measure the runout of the surface not 
rubbed by the brushes using a dial gauge.

Standard value: 0.05 mm or less
Limit: 0.1 mm

AK202890

B terminal

M terminal

S terminal

Field coil
lead

AB

AK202790

Socket wrench

Stop ring

Pinion Gear

Overrunning 
clutch

AB

AK202791

Snap ring 
pliers

Snap ring

Pinion gear

Overrunnning 
clutch

AB

AK202911

Overrunning 
clutch

Stop ring

Snap ring

Stop ring

AB

AK202712

STARTING SYSTEM

ENGINE ELECTRICAL

16-28

2. Measure the diameter of the commutator.

Standard value: 29.4 mm
Limit: 28.8 mm

3. Measure the depth of the undercut between 

segments.

Standard value: 0.5 mm
Limit: 0.2 mm

BRUSH HOLDER

Push the brush into the brush holder to make sure 
that the spring is working on the brush.
If the spring is not working, replace the brush holder.

OVERRUNNING CLUTCH

1. Make sure that the pinion cannot be turned 

counterclockwise and can be turned clockwise 
freely.

2. Check the pinion for abnormal ware and damage.

BRUSHES

1. Check the commutator contacting surface of each 

brush for abnormal roughness. Also check the 
height of the brush. Replace the brush holder if 
the height is lower than the limit.

Limit: 7.0 mm

2. When the contact surface of the brush is rectified 

or the brush holder is replaced, recondition the 
contact surface with sandpaper wrapped around 
the commutator.

AK202715

AK202711

Segment

Undercut

Mica

AB

AK202897

AK202710

Free

Lock

AB

AK202846

Brush 
height

AB