Mitsubishi Outlander GS45X. Manual - part 533

STARTING SYSTEM

TSB Revision

ENGINE ELECTRICAL

16-31

ON-VEHICLE SERVICE

STARTER RELAY CHECK

M1162001400875

Battery 
voltage

Terminal number to 
be connected to 
tester

Continuity test 
results

Not applied

3 

− 4

Open circuit

Connect 
terminal 2 to 
battery (+) 
terminal.
Connect 
terminal 1 to 
battery (

−) 

terminal.

3 

− 4

Continuity (less than 
2 ohms)

4

3

2

1

1

2

3

4

AC506970

AC505376

Starter relay

AI

<2.4L Engine>

AC703791

AC703792

4

2

3

1

1

2

3

4

Starter relay

AC

<3.0L Engine>

STARTING SYSTEM

TSB Revision

ENGINE ELECTRICAL

16-32

STARTER MOTOR ASSEMBLY INSPECTION

REMOVAL AND INSTALLATION <2.4L ENGINE>

M1162001002345

REMOVAL SERVICE POINT

.

<<A>> STARTER CONNECTOR AND TERMI-
NAL/STARTER ASSEMBLY REMOVAL

1. Slide the starter assembly, and disconnect the starter 

connector and terminal.

2. Remove the starter assembly from the lower front of the 

engine.

Pre-removal operation
• Air Cleaner Intake Duct and Air Cleaner Intake Hose 

Removal (Refer to GROUP 15, Air Cleaner <2.4L 

Engine>

P.15-4

).

• Battery and Battery Tray Removal (Refer to GROUP 54A, 

Battery 

P.54A-11

).

• Engine Room Under Cover Front A, B Removal (Refer to 

GROUP 51, Under Cover 

P.51-22

).

Post-installation operation
• Engine Room Under Cover Front A, B Installation (Refer 

to GROUP 51, Under Cover 

P.51-22

).

• Battery and Battery Tray Installation (Refer to GROUP 

54A, Battery 

P.54A-11

).

• Air Cleaner Intake Duct and Air Cleaner Intake Hose 

Installation (Refer to GROUP 15, Air Cleaner <2.4L 

Engine>

P.15-4

).

AC611210

36 ± 9 N·m
27 ± 6 ft-lb

11 ± 1 N·m
93 ± 13 in-lb

2

AB

3

1

Removal steps 

•

Emission vacuum hose and brake 
booster vacuum hose connection 
(Refer to GROUP 15, Intake 
Manifold <2.4L Engine>

P.15-9

).

•

Throttle body stay (Refer to 
GROUP 13A, Throttle Body 

P.13A-885

).

1.

Starter mounting bolts

<<

A

>>

2.

Starter connector and terminal 
connection

<<

A

>>

3.

Starter assembly

Removal steps (Continued)

STARTING SYSTEM

TSB Revision

ENGINE ELECTRICAL

16-33

REMOVAL AND INSTALLATION <3.0L ENGINE>

M1162001002594

REMOVAL SERVICE POINT

.

<<A>> STARTER ASSEMBLY REMOVAL

Remove the starter assembly from under the vehicle.

Pre-removal and Post-installation Operation
• Engine Room Under Cover Front Removal and Installa-

tion (Refer to GROUP 51, Under Cover 

P.51-22

). 

AC703793

1

2

3

36 ± 9 N·m
27 ± 6 ft-lb

5.0 ± 1.0 N·m
44 ± 9 in-lb

5.0 ± 1.0 N·m
44 ± 9 in-lb

11 ± 1 N·m
93 ± 13 in-lb

AB

36 ± 9 N·m
27 ± 6 ft-lb

Removal steps 

1.

Starter connector and terminal 
connection

2.

Starter cover

<<

A

>>

3.

Starter assembly

Removal steps (Continued)

STARTING SYSTEM

TSB Revision

ENGINE ELECTRICAL

16-34

INSPECTION

M1162001100830

.

PINION GAP ADJUSTMENT

1. Disconnect the lead wire from the M-terminal of the 

magnetic switch.

2. Connect a 12-volt battery between the S-terminal and 

M-terminal.

CAUTION

This test must be performed quickly (in less than 10 sec-
onds) to prevent the coil from burning.
3. Set the switch to "ON", and the pinion will move out.

4. Check the pinion-to-stopper clearance (pinion gap) with a 

feeler gauge.

Standard value: 0.5 

− 2.0 mm (0.02 − 0.07 inch)

5. If the pinion gap is out of specification, adjust by adding or 

removing gasket(s) between the magnetic switch and front 
bracket.

.

AKX01239

B

M

S

Battery

Switch

Starter
motor

Wire

AK

<2.4L engine>

AK305042AG

Switch

S

M

Wire

Battery

Starter
motor

B

<3.0L engine>

AK700044AB

Stopper

Pinion gap

Pinion

AK700045