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BATTERY/STARTER MOTOR/GENERATOR SERVICE
8B - 1
BATTERY/STARTER MOTOR/GENERATOR SERVICE
CONTENTS
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page
BATTERY SERVICE PROCEDURES ...........
ENGINE STARTER MOTOR SERVICE
PROCEDURES .........................
GENERATOR SERVICE PROCEDURES ........
SPECIFICATIONS ........................
BATTERY SERVICE PROCEDURES
GENERAL INFORMATION
This section covers Battery rermoval and installa-
tion procedures only. For diagnostic procedures. refer
to Group 8A - Battery/Starting/Charging Systems Di-
agnostics.
The Low Maintenance Battery (Fig. 1) has remov-
able battery cell caps. Water can be added to this
battery. The battery is not sealed and also has small
vent holes in the top. The chemical composition inside
of the battery produces an extremely small amount of
gases at normal charging voltages. The battery is
equipped with a test indicator (Fig. 1) that displays a
colored ball to indicate battery state-of-charge.
Green Indicator = Full charge
Black Indicator = Discharged
Yellow Indicator = Battery replacement required
Be sure vents are installed when washing bat-
tery to prevent solution from entering battery.
(2) Clean the outside of the battery case if the
original battery is to be installed. Clean the top cover
with diluted ammonia or a sodium bicarbonate/water
solution to remove the acid film (Fig. 2). Flush with
clean water. Ensure that the cleaning solution does
Fig. 2 Cleaning Battery
Fig. 1 Low Maintenance Battery
not enter the cells.
(3) Remove corrosion from the terminals with a
wire brush or post and terminal cleaner (Figs. 3 and
4). Inspect the case for cracks or other damage that
would result in leakage of electrolyte.
Check electrolyte level in the battery. Use a putty
knife or other suitable wide tool to pry filler caps off
low maintenance battery (Fig. 5). Do not use a screw-
driver. Add distilled water to each cell until the liquid
reaches the bottom of the vent well. DO NOT OVER-
FILL.
BATTERY MAINTENANCE
(1) Inspect the cable terminal for corrosion and
damage. Remove the corrosion using a wire brush, or
post and terminal cleaner, and a sodium
bicarbonate/water solution. Replace cables that have
damaged or deformed terminals.
 8B - 2 BATTERY/STARTER MOTOR/GENERATOR SERVICE
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Fig. 5 Removing Filler Cap
(3) If necessary, use a puller to remove the cable
terminal clamps, and remove the negative cable ter-
minal clamp first.
Fig. 3 Cleaning Battery Post
WARNING: WEAR A SUITABLE PAIR OF RUBBER
GLOVES (NOT THE HOUSEHOLD TYPE) WHEN RE-
MOVING A BATTERY BY HAND. IF THE BATTERY IS
CRACKED OR LEAKING THE ELECTROLYTE CAN
BURN THE SKIN.
(4) Remove battery holddowns and remove battery
from vehicle (Fig. 6).
(5) Inspect the battery tray and holddowns for cor-
rosion. Remove corrosion using a wire brush and a
sodium bicarbonate/water solution. Paint any exposed
bare metal. Replace damaged components (Fig. 6).
If the battery tray needs to be replaced, dis-
connect the hoses from the vacuum reservoir to
remove the tray. Remove the vacuum reservoir
from the bottom to the battery tray.
Fig. 4 Cleaning Battery Terminals
INSTALLATION
(1) Refer to Specifications to determine if the bat-
tery has the correct classification and rating for the
vehicle.
(2) Use a hydrometer to test the battery electrolyte.
Charge the battery if necessary.
(3) Position the battery in the tray. Ensure that the
positive and negative terminals (posts) are correctly
located. The cables must reach their respective termi-
nals (posts) without stretching (Fig. 7).
(4) Ensure that the tang at the battery base is
positioned in the tray properly before tightening the
holddown.
Operate the engine immediately after adding water
(particularly in cold weather) to assure proper mixing
of the water and acid.
BATTERY REPLACEMENT
REMOVAL
(1) Make sure ignition switch is in OFF position
and all electrical accessories are OFF.
(2) Loosen the cable terminal clamps.
CAUTION: It is imperative that the cables are con-
nected to the battery positive-to-positive and
negative-to-negative. Reverse polarity will damage
the generator diodes and radio(s).
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BATTERY/STARTER MOTOR/GENERATOR SERVICE
8B - 3
Fig. 7 Battery Cable Connections
m (75 in. lbs.).
(7) Apply a thin coating of petroleum jelly or chas-
sis grease to the cable terminals and the battery
posts.
(8) Inspect the negative cable connections on the
engine and the vehicle body for condition, security
and electrical continuity.
Fig. 6 Battery Tray and Holddown
(5) Place the felt washer on the positive battery
terminal.
(6) Connect the positive cable first. Then connect
the negative cable. Tighten both cable terminal bolts
to 8.5 N
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8B - 4 BATTERY/STARTER MOTOR/GENERATOR SERVICE
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ENGINE STARTER MOTOR SERVICE PROCEDURES
GENERAL INFORMATION
This section will cover the Starting System compo-
nent service procedures only. For diagnostic proce-
dures, refer to Group 8A - Battery/Starting/Charging
Systems Diagnostics.
The starter system circuits consist of:
The starter magnetic field is produced by six per-
manent magnets. The magnets are mounted in the
armature frame and positioned according to polarity.
They are permanently attached to the frame and are
not removable.
The starter motor is activated by a solenoid
mounted on the overrunning clutch housing.
This unit is highly sensitive to hammering, shocks,
and external pressure.
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a battery
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starter motor and solenoid
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starter relay
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ignition switch
park/neutral positon switch (automatic transmis-
sion)
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CAUTION: The starter motor MUST NOT BE
CLAMPED in a vise by the stator frame. Doing so
may damage the magnets. It may be clamped by the
mounting flange ONLY.
connecting wires and battery cables.
STARTER RELAY REPLACEMENT
The starter relay is located in the Power Distribu-
tion Center (Fig. 1). Refer to the underside of the
Power Distribution Cover for relay location.
(1) Disconnect negative cable from battery.
(2) Replace the relay.
(3) Connect battery cable.
(4) Test relay operation.
CAUTION: Do not connect the starter motor incor-
rectly when electrical tests are being performed. The
magnets may be damaged and rendered unservice-
able.
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Ensure cleanliness when performing repairs.
Metal chips are attracted by the magnets and may
not be completely removed from the stator frame.
Chips in the ring gear can lead to failure of the
starter.
STARTER MOTOR REMOVAL/INSTALLATION—4.0L
(1) Disconnect negative cable from battery.
(2) Raise and support vehicle.
(3) Disconnect the battery wire and solenoid feed
Fig. 1 Power Distribution Center
STARTER MOTOR GENERAL INFORMATION—4.0L
The Mitsubishi starter motor is a light-weight unit
featuring a planetary gear drive and permanent mag-
nets for current induction.
The planetary gear drive is splined to both the
armature shaft and overrunning clutch. Starter
torque is transmitted to the overrunning clutch pin-
ion through the planetary gears which provide higher
rotational speeds.
Fig. 2 Solenoid Harness Removal
wire connector (Fig. 2).
(4) Remove starter front mounting bolt (Fig. 3).
(5) Remove starter rear mounting bolt and remove
starter.
(6) To install the starter motor, reverse the removal
procedures and torque the mounting hardware as
follows:
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Tighten starter mounting bolts to 45 N
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m (33 ft. lbs.).
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BATTERY/STARTER MOTOR/GENERATOR SERVICE
8B - 5
Fig. 4 Solenoid Harness Removal—Typical
Fig. 3 Starter Motor Removal/Installation—Typical
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Tighten the terminal adapter solenoid nut to 6
N
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m (55 in. lbs.).
Tighten the terminal adapter battery cable nut to
10 N
m (90 in. lbs.).
(7) Remove vehicle support and lower vehicle.
(8) Install negative cable to battery.
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STARTER MOTOR GENERAL INFORMATION—5.2L
A Nippondenso reduction gear field coil starter mo-
tor is used on the 5.2L engine. This starter motor
features compact design and is lightweight as com-
pared with those having the same output. Structure
is different from that of direct drive and permanent
magnet type, but electrical wiring is common for all
engines. The reduction gear sets and solenoid shift
devices are enclosed in an aluminum die cast housing
which is part of starter assembly.
Fig. 5 Starter Motor Removal/Installation (Typical)
Tighten starter upper mounting bolt and stud nut
to 68 N
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m (50 ft. lbs.).
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Tighten the terminal adapter solenoid nut to 6
N
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m (55 in. lbs.).
Tighten the terminal adapter battery cable nut to
10 N
STARTER MOTOR REMOVAL/INSTALLATION—5.2L
(1) Disconnect negative cable from battery.
(2) Raise and support vehicle.
(3) Disconnect the battery wire and solenoid feed
wire connector (Fig. 4).
(4) Remove lower mounting nut (Fig. 5).
(5) Remove transmission line clip from stud.
(6) Remove upper mounting bolt.
(7) Pull starter forward and remove from vehicle.
(8) To install the starter motor, reverse the removal
procedures and torque the mounting hardware as
follows:
m (90 in. lbs.).
(9) Remove vehicle support and lower vehicle.
(10) Install negative cable to battery.
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PARK/NEUTRAL POSITION SWITCH
Refer to Group 21 for diagnostic, removal and in-
stallation procedures.
Check linkage adjustment before replacing
the switch.
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