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Type :
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Starter
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Specification :
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12V，2KW
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Number of feet :
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13T
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Brand :
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nuojin
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Number :
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1810A332
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Quality :
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renovate
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Delivery time :
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30day
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Turn off the vehicle, engage the handbrake, and shift to P/N gear; disconnect the negative battery terminal and insulate it to prevent short circuits.
Lift the vehicle to a safe height and support it with jack stands; remove the engine underguard/deflector, and clean oil stains and debris around the starter.
Tool list: socket/wrench set, torque wrench, Phillips/flathead screwdriver, rust penetrant, electrical tape, high-temperature grease, rags; the new starter must match the model of the old one. Check that the gears, terminals, and plugs are intact.
Power-off and Marking: Confirm that the negative battery terminal is disconnected; take photos to record the positions of the starter terminals (main cable terminals 30/50, small plug) and fixing bolts to avoid incorrect installation.
Disconnect Electrical Connections: Remove the terminal cover, unscrew the nut of the main cable (terminal 30) and disconnect the cable; pull out the small plug/connector of the solenoid switch, arrange the wiring harness and secure it to prevent damage from pulling.
Remove Fixing Bolts: There are usually 2 through bolts (mostly located at the bottom for L200/Fullback; slightly different for Pajero Sport depending on the model year/displacement). If the bolts are rusted, spray with rust penetrant and let it soak in, then loosen the bolts symmetrically and remove them. Take out the old starter carefully to avoid colliding with the flywheel ring gear.
Pre-installation Inspection and Lubrication: Clean the mounting surface and bolt threads; apply a small amount of high-temperature grease to the starter drive gear and splines (do not over-apply); confirm that the clearance between the new starter and the flywheel ring gear is normal and the solenoid switch operates smoothly.
Positioning and Tightening Bolts: Align the new starter with the mounting surface, insert the bolts and tighten them by hand, then use a torque wrench to fasten them in accordance with the manufacturer’s specifications (typical torque: 37 N·m for L200/Fullback; 35–40 N·m for Pajero Sport, refer to the vehicle manual for exact values). Tighten the bolts symmetrically in stages to avoid uneven loading.
Restore Electrical Connections: First, insert and lock the small plug of the solenoid switch; then connect the main cable to terminal 30 and tighten the nut to the specified torque (typically 9.8–10 N·m). Refit the terminal cover and secure the wiring harness clips to ensure no looseness or ground fault risk.
Reset Surrounding Components: Refit the engine underguard/deflector and reinstall other accessories in reverse order of removal.
Restore Power Supply: Reconnect and fasten the negative battery terminal, and check that all connections are tight.
Function Test: After power-on, gently turn the ignition switch to observe if the starter drives the flywheel smoothly without slipping or abnormal noise; conduct multiple start tests to confirm normal operation under both cold and hot engine conditions; check the battery voltage and terminal temperature rise for no abnormal heating or sparking.
Final Inspection: Clean up tools and the work area, confirm that no components are missing, and ensure the vehicle can start and run normally.
Starter fails to rotate: Check battery voltage, negative terminal grounding, tightness of the small plug and terminal 30; verify solenoid switch operation and the condition of fuses/relays.
Slipping/abnormal noise: Check for gear wear, flywheel ring gear tooth damage, or excessive mounting clearance; readjust or replace the relevant components as needed.
Overheating/ablation: Check for loose terminals, poor grounding, or internal short circuits in the starter; tighten the connections and conduct a test, replace the starter if necessary.
(Applicable to Mitsubishi L200 2.4L 2015-, Fiat Fullback 2.4L, Mitsubishi Pajero Sport)
Disconnect the negative battery terminal throughout the installation process and wrap the terminal with insulating tape to prevent accidental short circuits caused by grounding. Never plug or unplug the starter terminals when the power is on, as this may generate electric arcs that could burn components or even cause fires.
When installing: Connect the small solenoid switch plug first, then attach the main power cable to the terminal 30. When disassembling: Reverse the sequence (disconnect the main cable first, then pull out the small plug) to prevent the main cable from grounding and damaging the solenoid switch.
Tighten the nut of terminal 30 strictly within the torque range of 9.8–10 N·m. Loose fastening will lead to poor contact, overheating, and ablation, while over-tightening may strip the threads or damage the terminal.
Secure the wiring harness with original clips. Avoid contact or friction between the harness and high-temperature components (e.g., engine, exhaust pipe) or moving parts to prevent harness abrasion and short circuits.
After installation, confirm that the negative battery grounding point, starter housing, and engine block contact surfaces are clean and free of oil stains or rust. Polish the contact surfaces if necessary to ensure an unobstructed grounding circuit. Poor grounding will result in low starter rotation speed and weak starting performance.
Clean oil stains, rust, and sealant residues from the starter mounting flange and engine block contact surfaces to ensure tight fit. Align the positioning pins (if equipped) during installation. Do not force the bolts to align, as this may strip threads or deform the flange.
Tighten the fixing bolts symmetrically in stages to avoid uneven stress that could crack the starter housing. Follow the model-specific torque specifications strictly: 37 N·m for L200/Fullback; 35–40 N·m for Pajero Sport.
Use only original-specification bolts. Never mix bolts with mismatched lengths or diameters, as overly long bolts may damage internal engine components.
Apply a small amount of high-temperature grease only to the starter drive gear teeth and splines. Under no circumstances apply grease to the solenoid switch, carbon brushes, or terminals, as oil contamination can cause electrical faults.
Before installation: Manually rotate the flywheel and inspect the ring gear teeth for wear, missing teeth, or cracks.
After installation: Gently push the drive gear to verify that the meshing clearance with the ring gear is within the normal range (typically 0.5–1.5 mm). Excessive clearance will cause slipping and abnormal noise during startup, while insufficient clearance may lead to gear jamming.
Fiat Fullback 2.4L: It shares the same platform as the L200, so the installation procedure is identical. However, wiring harness routing varies slightly across some model years. Restore the harness according to photos taken before disassembly to avoid interference.
Mitsubishi Pajero Sport: For some model years, the intake manifold lower guard must be removed to access the starter. Protect surrounding pipelines (e.g., fuel pipes, vacuum pipes) during disassembly and assembly to prevent damage and leakage.
Never strike the starter housing or drive gear with a hammer, as this may damage internal components such as the rotor and stator windings.
Do not crank the starter continuously for extended periods: Limit single cranking time to no more than 5 seconds, with an interval of at least 30 seconds between attempts. Continuous cranking will overheat and burn out the starter. If the engine fails to start after multiple attempts, troubleshoot the issue instead of forcing further cranking.
Verify the compatibility of the new starter before installation: Confirm that its power rating (2KW), voltage (12V), and mounting hole positions match the original equipment. Do not use starters with mismatched specifications.
Never perform a no-load power-on test when the starter is not mounted to the engine. The drive gear may eject at high speed, posing a risk of personal injury or component damage.
After starting the engine, listen for abnormal noises from the starter (e.g., slipping, jamming sounds). Observe the terminals for signs of overheating or smoke.
During idle operation, check that the wiring harness does not interfere with moving parts such as pulleys.
References：
Mitsubishi Factory Workshop Manual: Search by vehicle model year/engine code (e.g., 4N15). It contains precise disassembly and assembly procedures, torque values, clearance parameters, and circuit diagrams. Access usually requires a paid subscription or can be obtained through authorized dealers/professional repair platforms.
Fiat Fullback: As it shares the same platform as the Mitsubishi L200, you can refer to the L200 workshop manual. Meanwhile, cross-check with Fiat’s supplementary technical bulletins to avoid discrepancies in details such as wiring harness routing.
Third-party repair databases (e.g., AllData, Mitchell): These provide structured disassembly/assembly guidelines and torque tables, making them ideal for professional repair technicians.
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