303-06 Starting System 303-06

SECTION: 303-06 Starting System

VEHICLE APPLICATION)*)DOFRQ
CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................303-06-1
DESCRIPTION AND OPERATION
Starting System — 6 Cylinder (Mitsubishi Electric) ..............................................................303-06-2
General Service ....................................................................................................................303-06-2
Description ...........................................................................................................................303-06-2
Operation .............................................................................................................................303-06-2
Roadside Service ..................................................................................................................303-06-3
Jump Starting .......................................................................................................................303-06-3
Connecting and Starting Procedure .....................................................................................303-06-3
Engine Starting .....................................................................................................................303-06-3
DIAGNOSIS AND TESTING
Starting System .....................................................................................................................303-06-4
Symptom Chart ...................................................................................................................303-06-4
Pinpoint Tests ......................................................................................................................303-06-4
Component Tests .................................................................................................................303-06-8
GENERAL PROCEDURES
Starting System ...................................................................................................................303-06-11
REMOVAL AND INSTALLATION
Starter Motor .......................................................................................................................303-06-12

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303-06-1 Starting System 303-06-1

SPECIFICATIONS

General Specifications
Description Specification
Free Run Test 11V
<= 90 A
>= 2850 RPM
0 Nm
Nominal Running Test - Load 1 7.5 V
<= 300 A
>= 840 RPM
8.8 Nm
Carbon Brush Length (Minimum) 5.5 mm
Solenoid Pull in @ 20 C (Pinion <= 8 V
travel restricted to 2mm)
Pinion Reset Positon (from starter 14.4 ± 1 mm
motor mounting surface)
Pinion Stop Position (from starter 26.4 ± 1mm
motor mounting surface)
Ring Gear Position - manual (from 17.88 ±
the rear face of the block) 1.01mm
Ring Gear Position - auto (from the 17.86 ±
rear face of the block) 1.64mm

Torque Specifications
Description Nm
Starter Retaining bolts 15 - 30
Solenoid Fixing Screws 4.1 - 7.6
Solenoid Terminal Studs Terminal 30: 9.8-11.8 Nm
Through Bolts 5.0 - 7.1
Brush holder fixing 2.4 - 4.4
screws

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303-06-2 Starting System 303-06-2

DESCRIPTION AND OPERATION

Starting System — 6 Cylinder General Service

(Mitsubishi Electric)
Description
The starting system includes the permanent magnet
gear-reduction starter with a solenoid-actuated drive, The function of the starting system is to crank the
the battery, a remote control starter switch (part of the engine at a high enough speed to permit it to start.
ignition switch), the neutral start switch (automatic The system contains the following components:
transmission), the starter relay, the heavy circuit starter motor and solenoid
wiring, the body electronics module (BEM) and the
power train control module (PCM).
Turning the ignition switch to the START position
actuates the starter relay, through the starter control
circuit. The starter relay then connects the battery to
the starter solenoid, causing it to energize.
When the starter solenoid is energized, a magnetic
field is created in the solenoid windings. The iron
plunger core is drawn into the solenoid coil and a
lever connected to the drive assembly engages the
drive pinion gear into the flywheel ring gear. When the
plunger is pulled all the way in, its contact disk closes
the circuit between the battery and motor feed
terminals. This sends current to the motor and the
drive pinion gear cranks the flywheel to start the
engine. When current flows to the motor, the solenoid Item Description
pull-in coil is bypassed and the hold-in coil keeps the
1 Terminal 30 - Battery ’+’
drive pinion gear engaged with the flywheel until the
ignition switch is released from the START position. 2 Terminal 50 - Solenoid ’+’
An overrunning clutch in the drive assembly protects 3 Terminal 45 - Switch to motor
the starter from excessive speeds during the brief 4 Magnets
period before the driver releases the ignition switch
from the START position (as the engine starts). starter relay
battery
inhibitor switch (auto trans)
electrical circuitry incorporating the ignition switch,
BEM and PCM V (’smartshield’), starter diode
and resistor. (Refer schematics section of this
manual).
Operation
Turning the ignition to the IGN or ACC position
activates the BEMs ’smartshield’ system (Refer to
Section 419-10.) and disarms the engine
immobilisation. If the inhibitor switch is closed, the
circuit is completed and current flows through the
starter relay. This, in turn, completes the circuit from
the battery to the starter solenoid. This connects the
battery to the starter motor. The starter utilises an
integral positive engagement drive.
The electrical circuit also incorporates a starter diode
and starter resistor connected to ground. This
completes the starter solenoid circuit through ground
after the solenoid is switched off to prevent any
voltage surges at the solenoid caused by back EMF.

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303-06-3 Starting System
DESCRIPTION AND OPERATION (Continued)
Roadside Service
Jump Starting
To avoid damage to the vehicle and battery or the
possibility of personal injury, follow these instructions
and precautions:
CAUTION: Hydrogen and oxygen gases are
produced during normal battery operation. The
gas mixture can explode if flames, sparks, or
cigarettes are brought near the battery in an
enclosed space, always provide ventilation and
shield your eyes.
Keep out of reach of children. Batteries contain
sulphuric acid. Avoid contact with skin, eyes or
clothing. Also, shield your eyes when working
near the battery to protect against possible
splashing of the acid solution. In case of acid
contact with skin, eyes or clothing, flush
immediately with water for a minimum of fifteen
minutes. If acid is swallowed, drink large
quantities of milk or water, followed by milk of
magnesia, a beaten egg, or vegetable oil. Call a
physician immediately.
NOTE: If instructions are not observed, damage to
electronic components may result. Ensure the battery
to be used for boosting is 12-volt and that the
negative terminal is grounded.
Remove the filler vent caps from both batteries and
place damp cloth over batteries. If the booster battery
is installed in another vehicle, do not allow the two
vehicles to touch. Turn off all unnecessary electrical
loads. Select neutral gear on manual transmission, or
’P’ (Park) position in automatic transmission, and
engage the parking brake on both vehicles.
Connecting and Starting Procedure
Connect the jumper leads in the exact sequence as
illustrated.
Connect end of jumper lead to the positive (+)
terminal of the discharged battery. (Red lead if
coloured).
Connect the other end of the same jumper lead to
the positive (+) terminal of the booster battery.
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303-06-3
Connect end of second jumper lead (Black if
coloured) to the negative (-) terminal of the
booster battery.
Connect the other end of the second jumper lead
to the engine of the vehicle with the discharged
battery - NOT TO THE NEGATIVE TERMINAL
OF THE DISCHARGED BATTERY.
Take care that the jumper clamps do not touch each
other or any metal on either vehicle, and are clear of
cooling fans and drive belt.
Do not lean over the battery when making
connections.
Engine Starting
First start the engine in the vehicle with the booster
battery and let it run for a few minutes. Then start the
engine in the vehicle with the discharged battery.
Leave the jumper leads connected until the engine
reaches idle speed (at least 1 minute) - otherwise
damage to the electrical system may occur.
Switch heater fan to max speed to ’load’ the vehicle’s
electrical system prior to disconnecting the jumper
cables.
Disconnect the cables in reverse order.
Do not disconnect or change over the discharged
battery while the engine is running - damage to the
electrical system may occur.
WARNING: Jump starting could be
dangerous if done incorrectly.
Do not attempt a jump-start if the discharged
battery is frozen or if the battery fluid level is low,
as the battery may rupture or explode.
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303-06-4 Starting System 303-06-4

DIAGNOSIS AND TESTING

Starting System

Symptom Chart
Symptom Chart - Starting System
Condition
Starter Motor Cranks Slowly
Starter Motor Does Not Crank But
Starter Solenoid Operates
Starter Motor Does Not Crank and
Starter Solenoid Does Not Click
Starter Motor Spins But Does Not
Crank Engine
Unusual Starter Motor Noise During
Starter Motor Overrun
Starter Motor Remains Engaged and
Runs with Engine
Source Action
Loose connections in starter solenoid GO to Pinpoint Test A.
battery feed or ground circuit.
Undercharged battery. (Battery acid in
all cells should have a specific gravity
reading greater than 1.20, with all cells
within 10 points variation).
Malfunctioning starter motor.
Voltage drop on power cable.
Loose or corroded connections at GO to Pinpoint Test B.
starter solenoid.
Undercharged battery
Malfunctioning starter motor.
Main power cable open circuit.
Loose or corroded battery cable GO to Pinpoint Test C.
connections.
Undercharged battery.
Faulty TR/NDS (neutral drive switch).
Faulty ignition circuit grounds.
Malfunctioning starter motor.
Poor earth circuit.
Malfunctioning starter drive. GO to Pinpoint Test D.
Damaged flywheel.
Starter motor improperly mounted. GO to Pinpoint Test E.
Malfunctioning starter motor.
Improper starter drive engagement to
flywheel.
Battery cable touching solenoid GO to Pinpoint Test F.
S-terminal (defective or mispositioned
battery cable).
Shorted turns in starter solenoid.

Starter Motor Noisy in Operation Worn or damaged ring gear. Inspect ring gear repair or replace as
Excessive clutch dust (Manual required.
Transmission)

Pinpoint Tests

PINPOINT TEST A : THE STARTER MOTOR CRANKS SLOWLY

Test Step Result / Action to Take

A1 CHECK BATTERY CONNECTIONS
Inspect the battery terminals for loose or corroded connections. Yes
Go to A2
Test voltage drop between battery negative terminal to case of starter
motor, should be < 300mV when cranking. No
Are the battery terminals clean and tight? CLEAN and TIGHTEN battery cable
connections.

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303-06-5 Starting System 303-06-5

DIAGNOSIS AND TESTING (Continued)

Test Step Result / Action to Take

A2 CHECK BATTERY
Check the battery state of charge. Yes
Go to A3
Battery acid in all cells should have a specific gravity reading greater
than 1.20, with all cells within 10 points variation. No
Load test the battery. CHARGE or REPLACE the battery.

Is the battery OK?

A3 CHECK STARTER MOTOR CONNECTIONS

Inspect the starter motor terminals for loose or corroded connections. Yes
Go to A4
Test voltage drop between battery postive terminal to solenoid main
terminal, should be <350mV when cranking. No
Are starter motor terminal connections clean and tight? CLEAN and TIGHTEN starter motor
connections.

A4 CHECK STARTER MOTOR

Check the starter cranking current draw, using a suitable digital Yes
multimeter and current clamp or by following starter load test REMOVE starter and test.
procedure detailed in Components Tests of this section. REPAIR or REPLACE.
Is the current draw lower than Specification? For more No
information see the Specifications Table in this section. Go to A5

A5 CHECK CURRENT DRAW

Remove the starter motor and check the starter current draw with no Yes
load, using a suitable digital multimeter and current clamp or by Engine has excessive friction. Refer to Section
following starter no load test procedure detailed in this section. 303-01.
Is the current draw to Specification? For more information see No
the Specifications Table in this section. Test starter REPAIR or REPLACE.

PINPOINT TEST B : STARTER MOTOR DOES NOT CRANK BUT STARTER SOLENOID OPERATES

Test Step Result / Action to Take

B1 CHECK STARTER MOTOR CONNECTIONS
Inspect the starter motor terminals for loose or corroded connections. Yes
Go to B2
Are starter motor terminal connections clean and tight?
No
CLEAN and TIGHTEN starter motor
connections.

B2 CHECK BATTERY
Check the battery state of charge. Yes
Go to B3
Battery acid in all cells should have a specific gravity reading greater
than 1.20, with all cells within 10 points variation. No
Load test the battery. CHARGE or REPLACE the battery.

Is the battery OK?

B3 CHECK SOLENOID
By-pass the solenoid with a heavy jumper cable. Yes
REPLACE solenoid.
Does the engine crank now?
No
Go to B4

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303-06-6 Starting System 303-06-6

DIAGNOSIS AND TESTING (Continued)

Test Step Result / Action to Take

B4 CHECK STARTER ENGAGEMENT
Is the starter engagement firm? Yes
Engine locked up. Refer to Section 303-01.

No
Remove starter and test.
REPAIR or REPLACE.

PINPOINT TEST C : THE STARTER MOTOR DOES NOT CRANK/THE SOLENOID DOES NOT CLICK

Test Step Result / Action to Take

C1 : CHECK BEM SMARTSHIELD STATE
Use WDS to monitor the theft status (THEFT _ S) PID. Yes
Go to C2
With the ignition switched on is the BEM status "mobilised"?
No
Refer Section 419-10 (BEM).

C2 CHECK FUSES
Ensure vehicle is in Park or Neutral (Auto. Trans.). Yes
REPLACE and RETEST.
Check all fuses in the vehicle.
Check all fuses in the vehicle. No
Go to C3

C3 CHECK ENGINE ENABLE INPUT

Use WDS to monitor the engine enable input signal No (ATS) PCM Yes
PID. Problem exists in ’Smartshield’ system or
communication between PCM and BEM.
With the ignition switched on is the ATS signal being received by
the PCM? No
Go to C4

C4 CHECK BATTERY CONNECTIONS

Inspect the battery terminals for loose or corroded connections. Yes
Go to C5
Are the battery terminals clean and tight?
No
CLEAN and TIGHTEN battery cable
connections.

C5 CHECK BATTERY
Check the battery state of charge. Yes
Go to C6
Battery acid in all cells should have a specific gravity reading greater
than 1.20, with all cells within 10 points variation. No
Load test the battery. CHARGE or REPLACE the battery.

Is the battery OK?

C6 CHECK POWER SUPPLY TO STARTER MOTOR

Key in OFF position. Yes
Go to C9
Disconnect the starter motor solenoid terminal 50 (connector C-11).
Key in START position. No
Go to C7
Measure the voltage at Connector C-11
Is the voltage greater than 10 volts?

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303-06-7 Starting System 303-06-7

DIAGNOSIS AND TESTING (Continued)

Test Step Result / Action to Take

C7 CHECK POWER SUPPLY TO STARTER MOTOR
With the vehicle in park and the handbrake on, bridge the starter relay Yes
across its switching circuit (relay pins 30 AND 87) with a heavy Go to C10
jumper cable.
No
Does the starter crank now? Go to C8

C8 CHECK THE STARTER CIRCUIT

Check continuity of circuit from fuse block to starter relay and from Yes
starter relay to starter motor solenoid. Go to C9
Is the circuit OK? No
Rectify and Retest.

C9 CHECK THE SOLENOID

With the vehicle in park and the handbrake on, bridge the starter Yes
motor battery connection to the solenoid terminal. REPLACE solenoid. Retest.
Does the engine crank? No
No Test starter motor.
REPAIR or REPLACE.

C10 CHECK POWER BETWEEN IGN & STARTER RELAY

With ignition switched to the start position, check the voltage at the Yes
starter motor relay (winding input). Go to C11
Is there greater than 8 volts? No
Check continuity of circuit from fuse through
ignition switch to relay.
Rectify and Retest.

C11 CHECK PCM STARTER RELAY SWITCHING

Use the WDS to monitor the starter relay enable starter signal Yes
(ENABLE_ S) PCM PID. Go to C12
With the ignition switched to the start position is the signal No
"ON"? Perform further PCM diagnostic tests.
Refer to Section 303-14.

C12 CHECK STARTER CIRCUIT

Ensure vehicle is in Park or Neutral (Auto. Trans.). Yes
Replace starter motor.
Check continuity of circuit from, PCM;
Is the circuit OK? No
Rectify and Retest.

PINPOINT TEST D : THE STARTER SPINS BUT THE ENGINE DOES NOT CRANK

Test Step Result / Action to Take

D1 CHECK BATTERY
Check the battery state of charge. Yes
Go to D2
Is the battery OK?
No
CHARGE or REPLACE the battery.

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303-06-8 Starting System
DIAGNOSIS AND TESTING (Continued)
Test Step
D2 CHECK FLYWHEEL
Remove the starter motor. Refer to procedure in this section.
Inspect the starter drive and flywheel for damage.
Is the starter drive or flywheel damaged?
PINPOINT TEST E : UNUSUAL STARTER NOISE DURING STARTER OVERRUN
Test Step
E1 CHECK STARTER MOTOR MOUNTING
Inspect the starter motor mounting.
Check the starter motor mounting bolts for looseness.
Is the starter motor mounted properly?
E2 CHECK STARTER DRIVE ENGAGEMENT
Remove the starter motor.
Inspect the starter drive and flywheel for damage. Refer to inspection
procedure in this section.
Are the starter drive and flywheel OK?
PINPOINT TEST F : STARTER MOTOR REMAINS ENGAGED AND RUNS WITH ENGINE
Test Step
F1 : CHECK STARTER MOTOR TERMINALS
Inspect the starter motor connectors for corrosion and incorrect
installation.
Are the starter motor connectors clean and installed properly?
Component Tests
Starter Motor Load Test
Conduct this test if the starter cranks slowly and it is
desired to compare current draw to specifications.
This test is performed with the starter motor fitted to
the vehicle.
1. Connect the starter motor tester equipment to the
vehicle’s battery. Ensure that current is not
flowing through the ammeter and heavy duty
carbon pile rheostat portion of starter tester
circuit, (rheostat at maximum counter clockwise
position).
2. Disconnect the push on blade connector at the
starter solenoid (terminal 50) and connect a
remote control starter switch from the positive
battery terminal to solenoid terminal 50.
3. Place transmission in neutral or park. With the
ignition off crank the engine using the remote
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303-06-8
Result / Action to Take
Yes
REPLACE as necessary.
No
Perform Bench Test procedures this section.
Result / Action to Take
Yes
Go to E2
No
REMOUNT or REPLACE the starter motor.
Yes
PERFORM the Bench Test procedures in this
section.
No
REPLACE as necessary.
Result / Action to Take
Yes
PERFORM the Bench Test procedures in this
section.
No
CLEAN or ADJUST starter motor connectors.
starter switch, and determine exact reading on
voltmeter.
NOTE: Ensure ignition switch is in the off position
and the solenoid terminal 50 connector has been
removed so that the engine does not start.
4. Disconnect battery to vehicle cables and reduce
resistance of carbon pile until voltmeter indicates
the same reading as that obtained while the
starter cranked the engine. The ammeter will
indicate starter current draw under load. Check
this value with value listed in specifications.
Starter Motor No Load Test (Bench Test)
The starter motor no load test will uncover such
conditions as open or shorted windings, rubbing
armature, and bent output shaft. The starter can be
tested, at no load, on the test bench only.
1. Clamp the starter motor securely in a starter test
bench.
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303-06-9 Starting System
DIAGNOSIS AND TESTING (Continued)
2. Connect Starter Tester to a fully charged battery
(Specific Gravity > 1.260) and connect the battery
positive to the battery supply (terminal 30) of the
starter motor and battery negative to the starter
motor case. Starter motor connection cables
should be large enough to carry high currents,
(equivalent to those used on the vehicle).
3. Connect a remote starter switch between the
solenoid terminal 50 and the power supply on
terminal 30.
4. Ensure that no current can flow through the
ammeter (rheostat at maximum counter clockwise
position). Engage the remote starter switch, the
pinion should shift to the crank position and the
FG00009 en
303-06-9
starter motor should operate smoothly. Determine
the exact reading on the voltmeter.
NOTE: The duration of this test should be as
short as possible.
5. Disconnect starter from battery then reduce
resistance of rheostat until voltmeter indicates the
same reading as that obtained while the starter
was running. The ammeter will indicate starter no
load current draw. Refer to specifications for a
comparative value.
6. If the current exceeds Specification, check for
rubbing armature, bent output shaft, binding
bearings, or shorts in armature or brush
assembly.
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303-06-10 Starting System 303-06-10

DIAGNOSIS AND TESTING (Continued)

Starter Solenoid Armature

Inspect the solenoid for damage and test the winding The commutator should be examined for any sign of
dc resistance. burned or darkened segments as this is usually an
indication of open circuited windings. Check for short
Hold-in Winding 0.754 - 0.866 Ohms. circuits using an armature growler or similar tester.
Test the insulation resistance to earth using a megger
Pull-in Winding 0.330 - 0.378 Ohms. or similar tester. Place one of the test probes on the
Test temperature +20°C commutator and the other on the shaft.
During hold in and pull in tests the solenoid is held A reading 1 MegOhm or greater should be expected.
vertically, i.e. plunger uppermost. It is recommended Using a 500v megger.
that a rubber band be installed to prevent the plunger Please refer to the Disassembly and Assembly
from flinging out during testing. section of this manual.
To test for short circuits, hold a piece of ferrous metal
over the winding as shown. Rotate the armature 360°.
A shorted winding will cause the metal to vibrate in 2
spots, i.e. the pitch of the winding.

Inhibitor Switch Test

On vehicles equipped with an automatic transmission,
apply the brakes and attempt to start the engine while
moving the selector lever through all ranges. This may
determine if the problem is caused by a maladjusted
or defective neutral-start switch. Refer to Section
307-01 for the adjustment of this switch.

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303-06-11 Starting System 303-06-11

GENERAL PROCEDURES

Starting System
Cleaning Components

CAUTION: The Armature, solenoid switch

and drive assembly components must not be
cleaned with spirit based agents, only clean rags
and compressed air must be used.
NOTE: All other mechanical components may be
cleaned using non volatile or low inflammable agents
in a well ventilated area, it is important that the parts
are thoroughly dried before assembly, take care not to
breath in the vapours.
Please observe the safety regulations and precautions
issued by the manufacturer of the cleaning agent in
use.
Brushes and brush holder Inspection
1. Check the brush holder for shorts to ground using
an insulation tester with a minimum AC voltage of
40 volts.
2. Ensure that the brushes move freely in their
holders and that the brushes are free from chips
and burn marks.
3. Check brush length if shorter than the minimum
length (5.5mm) replace the brush set.

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303-06-12 Starting System 303-06-12

REMOVAL AND INSTALLATION

Starter Motor
Removal
1. Disconnect Battery Negative Ground Cable.
2. Raise vehicle on hoist.
3. Disconnect starter cable and solenoid connector.
4. Remove starter retaining bolts and withdraw
starter.
Installation
1. Position starter and install retaining bolts. Torque
to Specification.
2. Install starter cable and solenoid connection.
3. Lower Hoist.
4. Reconnect Battery Negative Ground Cable.

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