Mitsubishi type
21Unscrew the pulley nut. To prevent the
shaft rotating, insert an Allen key in the end of
the shaft.
22Remove the spring washer, pulley, fan,
spacer and dust shield.
23Scribe an alignment mark along the length
of the alternator to facilitate reassembly of the
drive end housing, stator and rear housing.
24Unscrew the through-bolts and withdraw
the drive end housing from the rotor shaft.
25Remove the seal and spacer from the
rotor shaft.
26Remove the rotor from the rear housing
and the stator. This may require the
application of local heat to the rear housing
using a large soldering iron. Do not use a heat
gun, as this may result in damage to the
diodes.
27Unscrew the four securing bolts and
withdraw the diode pack stator assembly
from the rear housing.
28Unsolder the stator leads from the diode
pack terminals. Use a pair of pliers when
unsoldering to act as a heat sink, otherwise
damage to the diodes may occur (see
illustration).
29If the length of either brush is less than the
minimum given in the Specifications, the
brush box must be renewed.
30To renew the brush box, unsolder the
connection to the diode pack, and solder theconnection to the new brush box. Use a pair
of pliers as a heat sink to avoid damage to the
diodes.
31Examine the surfaces of the slip rings.
Clean them with a fuel moistened cloth, or if
necessary fine glasspaper and then the cloth.
32Solder the stator leads to the diode pack
terminals, again using a pair of pliers as a heat
sink.
33Refit the diode pack/stator assembly to
the rear housing and tighten the securing
bolts.
34Insert a thin rod (an Allen key is ideal)
through the hole in the rear housing to hold
the brushes in the retracted position.
35Fit the rotor to the rear housing and then
remove the temporary rod to release the
brushes.
36Reassemble the remaining components
by reversing the dismantling operations. Make
sure that the scribed marks are in alignment.
Removal
1Apply the handbrake, jack up the front of
the vehicle and support on axle stands (see
“Jacking and Vehicle Support”).
2Disconnect the battery negative lead.
3Working underneath the vehicle, unscrewthe nut and disconnect the main cable from
the starter solenoid (see illustration).
4Disconnect the ignition switch wire from the
solenoid.
5Unscrew the three mounting bolts and
withdraw the starter motor from the gearbox
bellhousing (see illustration).
Refitting
6Refitting is a reversal of removal.
1If the starter motor fails to operate first
check the condition of the battery.
2Check the security and condition of all
relevant wiring.
Solenoid check
3Disconnect the battery negative lead and all
leads from the solenoid.
4Connect a 3 watt test lamp and a 12 volt
battery between the starter terminal on the
solenoid and the solenoid body as shown
(see illustration). The testlamp should light. If
not, there is an open circuit in the solenoid
windings.
5Now connect an 18 watt testlamp between
both solenoid terminals (see illustration),
then energise the solenoid with a further lead
to the spade terminal. The solenoid should be
heard to operate and the testlamp should
light. Reconnect the solenoid wires.
On load voltage check
6Connect a voltmeter across the battery
terminals, then disconnect the low tension
lead from the coil positive terminal and
operate the starter by turning the ignition
switch. Note the reading on the voltmeter
which should not be less than 10.5 volts.
7Now connect the voltmeter between the
starter motor terminal on the solenoid and the
starter motor body. With the coil low tension
lead still disconnected operate the starter
and check that the recorded voltage is not
more than 1 volt lower than that noted in
paragraph 6. If the voltage drop is more than
1 volt a fault exists in the wiring from the
battery to the starter.
9Starter motor - testing in the
vehicle
8Starter motor - removal and
refitting
5•8Engine electrical systems
7.28 Stator-to-diode pack connections (A)
and brushbox-to-diode pack terminal (B) -
Mitsubishi alternator8.5 Unscrew the starter motor mounting
bolts
9.5 Starter motor solenoid continuity test
circuit
A Battery terminal
B Motor terminal
C Spade terminal
9.4 Starter motor solenoid winding test
circuit
A Battery terminal
B Motor terminal
C Spade terminal
8.3 Solenoid wiring connections on Lucas
M79 starter motor- CVH engine
