Mitsubishi Outlander GS45X. Manual - part 534

STARTING SYSTEM

TSB Revision

ENGINE ELECTRICAL

16-35

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.

.

AKX01243

B

M

S

Battery

Starter 
motor

Wire

AK

<2.4L engine>

AK305043AH

S

M

Wire

Battery

Starter
motor

B

<3.0L engine>

AKX01245

B

M

S

Battery

Starter 
motor

Wire

AK

<2.4L engine>

AK305044AH

S

M

Wire

Battery

Starter
motor

B

<3.0L engine>

STARTING SYSTEM

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ENGINE ELECTRICAL

16-36

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 carbon pile 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 

by 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.

AKX01247

S

M

B

Ammeter

Carbon-pile
rheostat

Battery

Starter
motor

Voltmeter

AK

A

V

<2.4L engine>

AK305045AH

S

A

M

V

B

Carbon-pile rheostat

Battery

Voltmeter

Ammeter

Starter
motor

<3.0L engine>

AKX01249

B

M

S

Battery

Starter 
motor

Wire

AK

<2.4L engine>

AK305046AH

S

M

Wire

Battery

Starter
motor

B

<3.0L engine>

STARTING SYSTEM

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ENGINE ELECTRICAL

16-37

DISASSEMBLY AND REASSEMBLY

M1162001200600

AK501908AD

2

16

17

18

19

15

13

12

20

4

14

11

1

5

6

8

7

9

10

3

5.8 ± 1.6 N·m
51 ± 14 in-lb

3.4 ± 1.0 N·m
30 ± 9 in-lb

5.8 ± 1.6 N·m
51 ± 14 in-lb

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. Packing A

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

<<

B>> >>A

<< 15. Snap ring

<<

B>> >>A

<< 16. Stop ring

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

Disassembly steps (Continued)

STARTING SYSTEM

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ENGINE ELECTRICAL

16-38

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

.

1. 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.

2. 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.

AK301505AF

Magnetic
stitch

B terminal

S terminal

Field coil 
lead

M terminal

AK304685

Socket wrench

Stop ring

Pinion Gear

Overrunning 
clutch

AE

AK304686

Snap ring 
pliers

Snap ring

Pinion gear

Overrunning 
clutch

AE