303-06

Starting System 303-06

SECTION 303-06: Starting System

VEHICLE APPLICATION: 2014 Falcon

CONTENTS PAGE
SPECIFICATIONS
General Specifications�������������������������������������������������������������������������������������������������������������������������� 303-06-01
Torque Specifications��������������������������������������������������������������������������������������������������������������������������� 303-06-01
DESCRIPTION AND OPERATION
Starting System I6 (Mitsubishi)������������������������������������������������������������������������������������������������������������303-06-02
General Service�������������������������������������������������������������������������������������������������������������������������������������303-06-02
DIAGNOSIS AND TESTING
Symptom Chart�������������������������������������������������������������������������������������������������������������������������������������303-06-04
Pinpoint Tests�����������������������������������������������������������������������������������������������������������������������������������������303-06-05
Component Tests
Starter Motor Load Test����������������������������������������������������������������������������������������������������������������������� 303-06-10
Starter Motor No Load Test (Bench Test)����������������������������������������������������������������������������������������� 303-06-10
Starter Solenoid......................................................................................................................................303-06-12
Inhibitor Switch Test...............................................................................................................................303-06-12
Armature..................................................................................................................................................303-06-12
GENERAL PROCEDURES
Jump Starting����������������������������������������������������������������������������������������������������������������������������������������� 303-06-13
Cleaning Starting Motor Components���������������������������������������������������������������������������������������������� 303-06-14
REMOVAL AND INSTALLATION
Starter Motor I6�������������������������������������������������������������������������������������������������������������������������������������� 303-06-15

Version: 2014 Falcon

303-06 Starting System 303-06-1

SPECIFICATIONS

General Specifications I6 (Mitsubishi) Torque Specifications

Description Specification Description Nm

11 V Starter motor retaining bolts 48
<= 90 A * Battery positive terminal
Free Run Test 11
>= 2850 RPM integral connector retaining nut

0 Nm * Solenoid terminal integral

7
connector retaining nut
7.5V
Starter motor bracket retaining
<= 300A 10
Nominal Running Test - Load 1 bolts
>= 840 RPM
8.8 Nm CAUTION
Carbon Brush Length 5.5 mm * Damage to the internal connections will
Solenoid Pull in @ 20 °C (Pinion occur if the torque values are exceeded.
<= 8 V
travel restricted to 2mm)
Pinion Reset Position (from
14.4 ± 1 mm
starter motor mounting surface)
Pinion Stop Position (from starter
26.4 ± 1 mm
motor mounting surface)
Ring Gear Position - Manual
17.88 ± 1.01 mm
(from the rear face of the block)
Ring Gear Position - Auto (from
17.86 ± 1.64 mm
the rear face of the block)

Torque Specifications

Description Nm
Starter motor retaining bolts 15 - 30
Solenoid fixing screws 4.1 - 7.6
Solenoid terminal studs (Terminal 30) 9.8 - 11.8
Through bolts 5.0 - 7.1
Brush holder fixing screws 2.4 - 4.4

Version: 2014 Falcon

303-06 Starting System 303-06-2
DESCRIPTION AND OPERATION
Starting System I6 (Mitsubishi)
The starting system includes the permanent magnet
gear-reduction starter with a solenoid-actuated
drive, the battery, a remote control starter switch
(part of the ignition switch), the neutral start switch
(automatic transmission), the starter relay, the heavy
circuit wiring, the body electronics module (BEM) and
the powertrain 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 pull-in coil is bypassed and the hold-in
coil keeps the drive pinion gear engaged with the
flywheel until the ignition switch is released from the
START position.
An overrunning clutch in the drive assembly protects
the starter from excessive speeds during the brief
period before the driver releases the ignition switch
from the START position (as the engine starts).
Version: 2014 Falcon
General Service
Description
The function of the starting system is to crank the
engine at a high enough speed to permit it to start.
The system contains the following components:
• Starter motor and solenoid
• Starter relay
• Battery
• Inhibitor switch (Auto trans)
• Electrical circuitry incorporating the ignition
switch, BEM and EEC V (‘smartshield’), starter
diode and resistor. (Refer to schematics section
of this manual).
1
2
3
4
AUS05626A
Item Description
1 Terminal 30 - Battery ‘+’
2 Terminal 50 - Solenoid ‘+’
3 Terminal 45 - Switch to motor
4 Magnets
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 utilizes 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.
303-06 Starting System 303-06-3
DIAGNOSIS AND TESTING
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
Starter Motor Noisy in
Operation
Version: 2014 Falcon
Possible Sources Action
• Loose connections in starter solenoid
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 • GO to Pinpoint Test A.
within 10 points variation).
• Malfunctioning starter motor.
• Voltage drop on power cable.
• Loose or corroded connections at
starter solenoid.
• Undercharged battery • GO to Pinpoint Test B.
• Malfunctioning starter motor.
• Main power cable open circuit.
• Loose or corroded battery cable
connections.
• Undercharged battery.
• Faulty TR/NDS (neutral drive switch). • GO to Pinpoint Test C.
• Faulty ignition circuit grounds.
• Malfunctioning starter motor.
• Poor earth circuit.
• Malfunctioning starter drive.
• GO to Pinpoint Test D.
• Damaged flywheel.
• Starter motor improperly mounted.
• Malfunctioning starter motor.
• GO to Pinpoint Test E.
• Improper starter drive engagement to
flywheel.
• Battery cable touching solenoid
S-terminal (defective or mispositioned
battery cable). • GO to Pinpoint Test F.
• Shorted turns in starter solenoid.
• Worn or damaged ring gear. • Inspect ring gear repair or
replace as required.
• Excessive clutch dust (Manual
Transmission)
303-06 Starting System 303-06-4

DIAGNOSIS AND TESTING (Continued)

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 Yes
connections.
GO to A2
• Test voltage drop between battery negative terminal
No
to case of starter motor, should be < 300mV when
cranking. CLEAN and TIGHTEN battery cable
connections.
• Are the battery terminals clean and tight?
A2 CHECK BATTERY
• Check the battery state of charge. Yes
• Battery acid in all cells should have a specific gravity Go to A3
reading greater than 1.20, with all cells within 10 points
No
variation.
CHARGE or REPLACE the battery.
• Load test the battery
• Is the battery OK?
A3 CHECK STARTER MOTOR CONNECTIONS
• Inspect the starter motor terminals for loose or Yes
corroded connections.
Go to A4
• Test voltage drop between battery postive terminal to
No
solenoid main terminal, should be <350mV.
CLEAN and TIGHTEN starter motor
• Are starter motor terminal connections clean
connections.
and tight?
A4 CHECK STARTER MOTOR
• Check the starter cranking current draw, using a Yes
suitable digital multimeter and current clamp or by
REMOVE starter and test.
following starter load test procedure detailed in
Components Tests of this section. REPAIR or REPLACE
• Is the current draw lower than Specification? No
For more information, see the Specifications
Go to A5
Table in this section.
A5 CHECK CURRENT DRAW
• Remove the starter motor and check the starter Yes
current draw with no load, using a suitable digital
Engine has excessive friction. For
multimeter and current clamp or by following starter
additional information, refer to section
no load test procedure detailed in this section.
303-01 of the 2014 Falcon Workshop
• Is the current draw to Specification? For Manual.
more information, see the Specifications
No
Table in this section.
Test starter REPAIR or REPLACE.


Version: 2014 Falcon

303-06 Starting System 303-06-5

DIAGNOSIS AND TESTING (Continued)

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 Yes
corroded connections.
Go to B2
• Are starter motor terminal connections clean
No
and tight?
CLEAN and TIGHTEN starter motor
connections.
B2 CHECK BATTERY
• Check the battery state of charge. Yes
• Battery acid in all cells should have a specific gravity Go to B3
reading greater than 1.20, with all cells within 10 points
No
variation.
CHARGE or REPLACE the battery.
• Load test the battery.
• Is the battery OK?
B3 CHECK SOLENOID
• By-pass the solenoid with a heavy jumper cable. Yes
• Does the engine crank now? REPLACE solenoid.
No
Go to B4
B4 CHECK STARTER ENGAGEMENT
• Is the starter engagement firm? Yes
Engine locked up. For additional
information, refer to section 303-01 of the
2014 Falcon Workshop Manual.
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 SMARTLOCK STATE
• Use WDS to monitor the theft status (THEFT _ S) PID. Yes
• With the ignition switched on is the BEM Go to C2
status “moblised”?
No
Refer to section 419-10 of the 2014 Falcon
Workshop Manual.
C2 CHECK FUSES
• Ensure vehicle is in Park or Neutral (Auto. Trans.) Yes
• Check all fuses in the vehicle. REPLACE and RETEST
No
Go to C3

Version: 2014 Falcon

303-06 Starting System 303-06-6

DIAGNOSIS AND TESTING (Continued)

Test Step Result / Action to take

C3 CHECK ENGINE ENABLE INPUT
• Use WDS to monitor the engine enable input signal Yes
No (ATS) PCM PID.
Problem exists in ‘Smartshield’ system or
• With the ignition switched on is the ATS signal communication between PCM and BEM.
being received by the PCM?
No
Go to C4
C4 CHECK BATTERY CONNECTIONS
• Inspect the battery terminals for loose or corroded Yes
connections.
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
• Battery acid in all cells should have a specific gravity Go to C6
reading greater than 1.20, with all cells within 10 points
No
variation.
CHARGE or REPLACE the battery.
• Load test the battery.
• Is the battery OK?
C6 CHECK POWER SUPPLY TO STARTER MOTOR
• Key in OFF position. Yes
• Disconnect the starter motor solenoid terminal 50 Go to C9
(connector C-11).
No
• Key in START position.
Go to C7
• Measure the voltage at Connector C-11
• Is the voltage greater than 10 volts?
C7 CHECK POWER SUPPLY TO STARTER MOTOR
• With the vehicle in park and the handbrake on, bridge Yes
the starter relay across its switching circuit (relay pins
Go to C10
30 AND 87) with a heavy 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 Yes
relay and from 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 Yes
the starter motor battery connection to the solenoid
REPLACE solenoid. Retest.
terminal.
No
• Does the engine crank?
Test starter motor.
REPAIR or REPLACE.

Version: 2014 Falcon

303-06 Starting System 303-06-7

DIAGNOSIS AND TESTING (Continued)

Test Step Result / Action to take

C10 CHECK POWER BETWEEN IGN & STARTER RELAY
• With ignition switched to the start position, check the Yes
voltage at the 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 EEC STARTER RELAY SWITCHING
• Use the WDS to monitor the starter relay enable Yes
starter signal (ENABLE_ S) PCM PID.
Go to C12
• With the ignition switched to the start position
No
is the signal “ ON”?
Perform further PCM diagnostic tests.
For additional information, refer to section
303-14 of the 2014 Falcon Workshop
Manual.
C12 CHECK STARTER CIRCUIT
• Ensure vehicle is in Park or Neutral (Auto. Trans.). Yes
• Check continuity of circuit from, PCM. Replace starter motor.
• 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
• Is the battery OK? Go to D2
No
CHARGE or REPLACE the battery.
D2 CHECK FLYWHEEL
• Remove the starter motor. Refer to procedure in this Yes
section.
REPLACE as necessary.
• Inspect the starter drive and flywheel for damage.
No
• Is the starter drive or flywheel damaged?
Perform Bench Test procedures this
section.

Version: 2014 Falcon

303-06 Starting System 303-06-8

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST E : UNUSUAL STARTER NOISE DURING STARTER OVERRUN

Test Step Result / Action to take

E1 CHECK STARTER MOTOR MOUNTING
• Inspect the starter motor mounting. Yes
• Check the starter motor mounting bolts for Go to E2
looseness.
No
• Is the starter motor mounted properly?
REMOUNT or REPLACE the starter motor.
E2 CHECK STARTER DRIVE ENGAGEMENT
• Remove the starter motor. Yes
• Inspect the starter drive and flywheel for damage. PERFORM the Bench Test procedures in
Refer to Inspection Procedure in this section. this section.
• Are the starter drive and flywheel OK? No
REPLACE as necessary.
PINPOINT TEST F : STARTER MOTOR REMAINS ENGAGED AND RUNS WITH ENGINE

Test Step Result / Action to take

F1 CHECK STARTER MOTOR TERMINALS
• Inspect the starter motor connectors for corrosion Yes
and incorrect installation.
PERFORM the Bench Test procedures in
• Are the starter motor connectors clean and this section.
installed properly?
No
CLEAN or ADJUST starter motor
connectors.

Version: 2014 Falcon

303-06 Starting System 303-06-9
DIAGNOSIS AND TESTING (Continued)
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 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 park. With the ignition off
crank the engine using the remote 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.
Version: 2014 Falcon
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.
2. Connect Starter Tester to a fully charged battery
(Specific Gravity > 1260) 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 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.
303-06 Starting System 303-06-10

DIAGNOSIS AND TESTING (Continued)

STARTER MOTOR
TESTER

TERMINAL 50
REMOTE
STARTER
SWITCH

POSITIVE BATTERY
TERMINAL

TERMINAL 50

NEGATIVE BATTERY
TERMINAL

AUS00905

Version: 2014 Falcon

303-06 Starting System 303-06-11

DIAGNOSIS AND TESTING (Continued)

Starter Solenoid
Inspect the solenoid for damage and test the winding
DC resistance.

Hold-in Winding 0.754 - 0.866 Ohms.

Pull-in Winding 0.330 - 0.378 Ohms.
Test temperature +20°C
During hold in and pull in tests the solenoid is held
vertically, ie plunger uppermost. It is recommended
that a rubber band be installed to prevent the plunger
from flinging out during testing.
Inhibitor Switch Test
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. For
additional information, refer to section 307-01 of the
2014 Falcon Workshop Manual.
Armature
The commutator should be examined for any sign of
burned or darkened segments as this is usually an
indication of open circuited windings. Check for short
circuits using an armature growler or similar tester.
Test the insulation resistance to earth using a megger
or similar tester. Place one of the test probes on the
commutator and the other on the shaft.
A reading of 1 Mega Ohms or greater should be
expected when using a 500V megger.
Please refer to the Disassembly and Assembly
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 short winding will cause the metal to vibrate
in 2 spots, ie. the pitch of the winding.

AUS05011

Version: 2014 Falcon

303-06 Starting System 303-06-12

GENERAL PROCEDURES

Jump Starting To Connect the Booster Cables

To avoid damage to the vehicle and battery or the
possibility of personal injury, follow these instructions
and precautions.

CAUTIONS
Hydrogen and oxygen gases are generated
during normal battery operation. The gas
mixture can explode if flames, sparks or cigarettes A
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 C
the battery to protect against possible splashing of
the acid solution. Incase of acid contact with the skin, D
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
the electronic components may result. Ensure the B
battery to be used for boosting is a 12-volt and the
negative terminal is grounded.
Remove the filler vent caps from both the battery
and place a damp cloth over batteries. If the booster
battery id installed in another vehicle, do not allow
the two vehicle to touch. Turn off all unnecessary E102925
electrical loads. Select the park (P) position in the
automatic transmission and engage the parking A Flat battery vehicle
brake on both vehicles.
B Booster battery vehicle
WARNING
C Positive connection cable
Jump starting could be dangerous if done
D Negative connection cable
incorrectly. Do not attempt a jump-start if the
discharged battery is frozen or if the battery fluid level 1. Position the vehicles so that they do not touch
is low, as the battery may rupture or explode. one another.

CAUTIONS 2. Switch off the engine and any electrical

Connect batteries with only the same nominal
voltage.
Always use booster cables with insulated
clamps and adequate size cable.
Do not disconnect the battery from the
vehicle’s electrical system.
equipment.
3. Connect the positive (+) terminal of vehicle B with
the positive (+) terminal of vehicle A (cable C).
4. Connect the negative (-) terminal of vehicle B to
the ground connection of vehicle A (cable D).
CAUTIONS
Do not connect to the negative (–) terminal of
the flat battery.
Make sure that the cables are clear of any
moving parts.
To start the engine
1. Run the engine of vehicle B at moderately high
engine speed.
2. Start the engine of vehicle A.

Version: 2014 Falcon

303-06 Starting System 303-06-13

GENERAL PROCEDURES (Continued)

3. Run both vehicles for a minimum of three

minutes before disconnecting the cables.

CAUTION
Do not switch on the headlamps when
disconnecting the cables. The peak voltage
could blow the bulbs.
4. Disconnect the cables in the reverse order.
Cleaning Starting Motor 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 breathe in the vapour.
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 are free from chips and burn marks.
3. Check brush length. If it is shorter than the
minimum length of 5.5mm, replace the brush set.

Version: 2014 Falcon

303-06 Starting System 303-06-14

REMOVAL AND INSTALLATION

Starter Motor I6 (Mitsubishi)

Removal
1. Disconnect the Battery Negative Ground Cable.
For additional information, refer to section 414-01
of the 2014 Falcon Workshop Manual.

WARNING
Do not work on or under a vehicle supported
only by a jack. Always support the vehicle on
safety stands.
2. Raise the vehicle. For additional information, refer
to section 100-02 of the 2014 Falcon Workshop
Manual.
3. Remove the engine stone-tray.
4. Disconnect the starter cable, solenoid connector
and detach electronic connector.
5. Remove the two starter motor retaining bolts and
withdraw the starter motor.
Installation
1. Position the starter motor and install the retaining
bolts. Torque to specification.
2. Install the starter cable, solenoid connection and
the electronic connector.
3. Lower the vehicle. For additional information,
refer to section 100-02 of the 2014 Falcon
Workshop Manual.
4. Reconnect Battery Negative Ground Cable. For
additional information, refer to section 414-01 of
the 2014 Falcon Workshop Manual.

Version: 2014 Falcon