1991 MITSUBISHI MONTERO oil

STA R TE R

1991 M it s u bis h i M onte ro
ELECTRICAL
Starters
Diamante, Eclipse, Expo/Expo LRV, Galant, Mirage, Montero,
Pickup, Precis, 3000GT
DESCRIPTION
Starter is a conventional 12-volt, 4-pole brush-type motor,
with direct or gear reduction drive. The starter-mounted solenoid
shifts overrunning clutch and pinion into flywheel when starter is
energized.
TROUBLE SHOOTING
NOTE: See the TROUBLE SHOOTING - BASIC PROCEDURES article
in the GENERAL TROUBLE SHOOTING section.
NO LOAD TEST
CAUTION: Perform tests in less than 10 seconds to prevent coil
damage.
1) Install starter in soft-jawed vise. Connect starter in
series with a fully charged 12-volt battery. Connect a 100-amp ammeter
and carbon pile rheostat in series with positive battery post and
starter motor terminal. See Fig. 1.
2) Install voltmeter across starter motor. Adjust carbon pile
rheostat to full resistance. Connect cable from starter motor body to
negative battery terminal. Adjust carbon pile rheostat to proper test
voltage. See STARTER NO LOAD SPECIFICATIONS table.
3) Note that maximum amperage is within specification and
starter rotates smoothly. See STARTER NO LOAD SPECIFICATIONS table.
Fig. 1: Starter No Load Test Connections
Courtesy of Chrysler Motors.
STARTER NO LOAD SPECIFICATIONS

STARTER NO LOAD SPECIFICATIONS








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Starter Test Maximum Amps @
Application Type (1) Voltage Minimum RPM
Diamante ............ GR .......... 11 .......... 90 @ 3000
Expo/Expo LRV
1.8L ............. DD ......... 11.5 ......... 53 @ 6000
1.8L ............. GR .......... 11 .......... 90 @ 3000
2.4L ............. DD ......... 11.5 ......... 60 @ 6600
2.4L ............. GR .......... 11 .......... 90 @ 3000
Eclipse
1.8L .............. DD ......... 11.5 ......... 60 @ 6600
2.0L .............. GR .......... 11 .......... 90 @ 3000
Galant
A/T & M/T DOHC .... GR .......... 11 .......... 90 @ 3000
M/T SOHC .......... DD ......... 11.5 ......... 60 @ 6600
Mirage
1.5L
A/T ............. DD ......... 11.5 ......... 60 @ 6600
M/T ............. DD ......... 11.5 ......... 60 @ 6500
1.6L .............. GR .......... 11 .......... 90 @ 3000
Montero ............. GR .......... 11 .......... 90 @ 3000
Pickup
2.4L A/T & 3.0L ... GR .......... 11 .......... 90 @ 3000
2.4L M/T .......... DD ......... 11.5 ......... 60 @ 6600
Precis
A/T ............... DD ......... 11.5 ......... 60 @ 6600
M/T ............... DD ......... 11.5 ......... 60 @ 6500
3000GT .............. GR .......... 11 .......... 90 @ 3000
( 1) - The letters DD indicates direct drive and GR indicates gear
reduction.









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PULL-IN COIL TEST
CAUTION: Perform tests in less than 10 seconds to prevent coil
damage.
1) Disconnect field coil wire from terminal "M" at starter
solenoid. See Fig. 2. Connect jumper wire between positive battery
terminal of 12-volt battery and terminal "S" of solenoid.
2) Connect a second jumper wire from negative battery
terminal and touch terminal "M" of starter solenoid. See Fig. 2. If
solenoid plunger moves inward, solenoid is good. If not, replace
solenoid.
Fig. 2: Starter Solenoid Terminal Identification
Courtesy of Chrysler Motors.
HOLD-IN COIL TEST

CAUTION: Perform tests in less than 10 seconds to prevent coil
damage.
1) Disconnect field coil wire from terminal "M" at starter
solenoid. See Fig. 2. Connect jumper wire between positive battery
terminal of 12-volt battery and terminal "S" of starter solenoid.
2) Connect a second jumper wire from negative battery
terminal and touch starter case. If solenoid plunger is pulled-in,
hold-in coil is good. If not, replace solenoid.
RETURN TEST
CAUTION: Perform tests in less than 10 seconds to prevent coil
damage.
1) Disconnect field coil wire from terminal "M" at starter
solenoid. See Fig. 2. Connect jumper wire between positive battery
terminal of 12-volt battery and terminal "M" of starter solenoid.
2) Connect a second jumper wire from negative battery
terminal and touch starter case. Pull pinion outward and release it.
Replace solenoid if pinion remains outward.
PINION GAP CHECK
1) Disconnect field coil wire from terminal "M" at starter
solenoid. See Fig. 2. Connect jumper wire between positive battery
terminal of 12-volt battery and terminal "S" of starter solenoid.
2) Connect a second jumper wire from negative battery
terminal and touch terminal "M" of starter solenoid. See Fig. 2.
Measure clearance between pinion and stopper. See Fig. 3.
3) Clearance should be within specification. See STARTER
SPECIFICATIONS table. Adjust clearance by adding or removing gaskets
between solenoid and front housing.
Fig. 3: Measuring Pinion Gap
Courtesy of Mitsubishi Motor Sales of America.
REMOVAL & INSTALLATION

Remove negative battery cable. If necessary, raise vehicle on
hoist. Remove starter mounting bolts and starter. To install, reverse
removal procedure.
NOTE: On Raider models with A/T, it may be necessary to disconnect
transmission oil cooler line for starter removal.
OVERHAUL
Check commutator for out-of-round and proper amount of
undercut. Replace or repair armature if not within specification. See
STARTER SPECIFICATIONS table. Ensure brushes are not worn beyond wear
line (outer line closest to commutator contact surface). Check pinion
gap. See PINION GAP CHECK in this article.
DISASSEMBLY
NOTE: Procedures may vary slightly between conventional and
reduction gear starters.
1) Loosen nut securing connecting plate-to-magnetic switch
"M" terminal. Remove screws securing magnetic switch and remove switch
(solenoid) assembly. Remove through bolts and brush cover assembly.
Tap yoke assembly loose with wooden mallet. Remove yoke, armature
assembly and pinion shift lever.
2) Remove pinion stop ring from end of armature shaft by
pushing stop ring to clutch side. Remove snap ring and overrunning
clutch assembly from armature shaft.
Fig. 4: Disassembled View of Typical Mitsubishi Starter
CLEANING & INSPECTION
Clean all parts. Do not use grease dissolving solvent on

overrunning clutch, armature assembly, solenoid assembly or field
coils due to possible damage. Inspect all parts for damage or wear and
replace as required.
BENCH TESTS
Brushes & Springs
Check brush spring tension using a spring scale. Check brush
contact surface condition and brush length. Check lead clip and wire
connections and condition of brush holders. Replace as required. See
Brush Spring Tension and Minimum Brush Length Charts.
BRUSH & SPRING SPECIFICATIONS
BRUSH SPRING TENSION








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Application Ozs. (g)
Chrysler Corp. Imports ............ 46-59 (1302-1670)









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MINIMUM BRUSH LENGTH ( 1)








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Application In. (mm)
Chrysler Corp. Imports ................... .45 (11.5)
(1) - Minimum brush length should coincide with the
brush wear mark.









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Armature
Check external condition of armature for scoring or other
damage. Measure shaft distortion with dial indicator. Replace armature
if shaft distortion exceeds .004" (.10 mm).
Commutator
1) Inspect commutator for roughness, grooves, burns or
pitting. Sand lightly with 500 grit sandpaper if necessary. Check
commutator for out-of-round and mica insulators undercut to a depth of
.020-.031" (.5-.8 mm).
2) If necessary, commutator may be turned less than .04" (1
mm) from original size and mica undercut. Replace if excessively worn.
Field Coil
1) Check field coil continuity by connecting test probe of
circuit tester or an ohmmeter to the field coil positive terminal and
brush holder. If circuit is open, replace field coil.
2) Check for grounding of field coils by placing one probe of
circuit tester on starter housing and other probe to field coil
positive terminal. If little or no resistance, field coil is grounded
and must be replaced.
Overrunning Clutch Assembly
1) Inspect pinion assembly and sleeve. Sleeve should slide
freely on armature shaft and spline. If damage or resistance is noted,
replace assembly.
2) Check pinion and flywheel teeth for excessive rubbing or
damaged teeth. Replace as required.
Pinion Gear Clearance
The clearance between the pinion gear and pinion stopper

collar should be .02-.08" (.51-2.03 mm) on Mitsubishi starters, when
solenoid is engaged. Adjust as necessary by changing shims between
solenoid and starter yoke.
Fig. 5: Measuring Pinion Gear-to-Pinion Stopper Clearance
Pinion Case Bearing
Inspect bearing for wear and check side play. If clearance
exceeds .008" (.2 mm), replace bearing. New bearing clearance should
be .002-.004" (.05-.10 mm) for Mitsubishi starters.
NOTE: Ensure that bearing is installed so that end of bearing is
flush with gear case end.
REASSEMBLY
To reassemble, reverse disassembly procedure. Fill gear case
on reduction gear models with grease. Lightly oil pinion and all
bearing surfaces.

Lubricate ball joint with SAE J310 NLGI No. 2 grease. Apply
semi-drying sealant to ball joint grooves. Reverse removal procedure
to complete installation. Tighten bolts to specification. See TORQUE
SPECIFICATIONS table at end of article.
NOTE: On Ram-50 and Pickup, replace upper control arm if ball
joint is defective.
UPPER BALL JOINT R & I (MONTERO)
REMOVAL
Remove snap ring and dust cover together from ball joint. See
Fig. 1 . Use Ball Joint Remover/Installer (MB990799-01 and MB990800-01)
and Clamp (MB990840-01) to press ball joint from control arm. Tighten
clamp to remove ball joint.
INSTALLATION
1) Before installing, align reference mark on ball joint with
center of control arm. Using bushing remover/installers, install ball
joint in control arm. See Fig. 1.
2) Install snap ring on ball joint. Lubricate ball joint with
SAE J310 NLGI No. 2 grease. Apply semi-drying sealant to ball joint
grooves. Install new dust cover and ring.
AUTOMATIC TYPE LOCKING HUB R & I
REMOVAL
1) Place hub must in the FREE position by placing transfer
case lever in 2H position and moving vehicle in Reverse approximately
4-6 feet.
2) Remove cover from locking hub. If necessary, wrap shop
towel around cover and use an oil filter wrench to loosen cover. Raise
and support vehicle. Remove wheel assembly.
3) Using snap ring pliers, remove snap ring and shim from end
of drive axle. See Fig. 2. Using hexagonal wrench, remove locking hub
retaining bolts. Remove locking hub assembly.
Fig. 2: Exploded View of Automatic Locking Hub
Courtesy of Chrysler Motors.
INSTALLATION

REMOVAL
Remove skid plate (if equipped). Remove stabilizer bar bolt
from lower control arm. Remove stabilizer bar clamp-to-hanger bolts.
Remove stabilizer bar and bushings. Remove stabilizer bar-to-frame
hangers (if necessary).
INSTALLATION
Inspect bushings for wear. Check stabilizer bar for
deformation. To install, reverse removal procedure. Install stabilizer
bar-to-frame hangers and stabilizer bar-to-control arm bolt using new
nuts. Tighten hanger-to-frame nut and stabilizer bar-to-control arm
nut until distance from threaded end of bolt to nut is .24-.32" (6.1-
8.1 mm).
STEERING KNUCKLE R & I
REMOVAL
1) Raise and support vehicle. Remove wheel assembly. Remove
brake caliper. Remove hub/rotor assembly. See WHEEL BEARINGS under
REMOVAL & INSTALLATION. Remove dust cover from steering knuckle.
2) Disconnect tie rod end from steering knuckle. Loosen
torsion bar anchor arm assembly adjusting nut. Loosen ball joint-to-
steering knuckle nuts. Using ball joint separator, separate ball
joints from steering knuckle.
3) Detach upper and lower ball joints from steering knuckle.
Remove steering knuckle from drive axle. Remove oil seal and spacer
from steering knuckle.
INSPECTION
Inspect steering knuckle for cracks. Inspect spindle and
steering knuckle needle bearing for wear or damage.
INSTALLATION
1) If needle bearing requires replacement, drive bearing from
steering knuckle. Use Bearing Driver (MB990956-01) and Handle
(MB9909938-01) to install needle bearing.
NOTE: DO NOT reuse steering knuckle bearing if removed.
2) Using bearing installer and handle, install new needle
bearing until bearing is even with steering knuckle end face. Apply
SAE J310 NLGI No. 2 grease to bearing roller surface and spacer-to-
steering knuckle contact areas. Install spacer with chamfered side
toward inside of vehicle.
3) Using Seal Installer (MB990985-01) and Handle (MB990938-\
01), install seal in steering knuckle until seal is even with steering
knuckle end face. Apply grease to seal lip area and inside of seal. To
complete installation, reverse removal procedure. Tighten bolts to
specification. See TORQUE SPECIFICATIONS table at end of article.
TORSION BAR R & I
CAUTION: Mark torsion bar and anchor arm location for reassembly
reference before removing.