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Type :
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ENGINE STARTER
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Specification :
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Number of feet :
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Brand :
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NUOJIN
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Number :
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SH02-18-400
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Quality :
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Remanufacture
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Delivery time :
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30DAYS
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Tools and Materials PreparationNecessary tools: Socket wrench (selected according to bolt specifications, usually 10mm, 12mm, 14mm), torque wrench, Phillips/flathead screwdriver, extension bar, universal joint, crowbar (optional), multimeter.Auxiliary materials: New starter original gasket (if available), medium-strength thread locker (e.g., Loctite 243), rust inhibitor, cleaning cloth, battery ground wire (for emergency use).
Safety InspectionDisconnect the negative terminal of the vehicle battery (to avoid short circuit or accidental activation of the starter), and confirm the battery is powered off before operation.Clean the starter installation area, remove dust, oil stains or rust, and check the condition of the flywheel ring gear (replace the ring gear if severely worn, otherwise the starter will grind gears during meshing).Verify the new starter model: Confirm the 12V voltage and 1.9KW power are compatible with the engine (e.g., Mitsubishi 4G63/4G64 models), and check the alignment of mounting holes and matching of drive gear teeth with the flywheel.
Remove the starter power cable: Loosen the nut connecting the positive battery terminal to the starter solenoid "B+" terminal with a socket wrench, remove the cable (mark it to avoid incorrect connection).Remove the control wire: Unplug the connector from the solenoid "SW" terminal (or loosen the control wire nut), and separate the wiring harness connector.Remove the mounting bolts: The starter is usually fixed to the engine block/transmission housing with 2 main mounting bolts. Loosen and remove the bolts with a socket wrench, and hold the starter to prevent it from falling.Take out the old starter: Slowly separate the starter from the mounting seat, check for cracks or deformation on the mounting seat surface, and clean residual gasket material.
Pre-installation PreparationIf the new starter comes with a gasket, attach it between the mounting seat and the starter housing (install directly without a gasket if none is provided, ensuring the contact surface is clean).Apply a small amount of medium-strength thread locker to the threads of the mounting bolts (to prevent loosening from vibration), taking care not to let the thread locker enter the starter interior.
Positioning and FixingHold the new starter, align it with the engine mounting holes, face the drive gear end toward the flywheel ring gear, and slowly push it into the mounting seat.Insert the 2 main mounting bolts, hand-tighten them into the threads first (to avoid thread stripping), then tighten them to the specified torque with a torque wrench (25-35N·m for Mitsubishi models, refer to the engine repair manual for details), and tighten in a diagonal sequence to ensure even force distribution.
Wiring ConnectionConnect the power cable: Reattach the positive battery cable to the starter "B+" terminal, tighten the nut (torque 8-12N·m), and ensure the connection is secure (to avoid overheating and ablation).Connect the control wire: Insert the wiring harness connector into the solenoid "SW" terminal (or tighten the control wire nut), and confirm the connector is locked in place (to prevent poor contact).Inspect the wiring harness: Organize the wiring harness around the starter, avoid interference with high-temperature engine components (e.g., exhaust pipe) or moving parts (e.g., flywheel), and secure excess wiring with cable ties.
Mechanical InspectionTurn the crankshaft (by turning the crankshaft pulley with a wrench), check the meshing clearance between the starter drive gear and the flywheel ring gear (normal clearance 0.5-1.5mm), ensuring no jamming or abnormal noise.Check the grounding between the starter housing and the engine (install a grounding gasket if necessary).
Electrical TestingReconnect the negative battery terminal, turn the ignition switch to the "ON" position, and ensure the instrument lights turn on normally (confirm no short circuit in the circuit).Start the engine: Turn the ignition switch (or press the start button) – the starter should quickly crank the engine without abnormal noise or slipping; the drive gear should retract immediately after startup.Multiple startup tests: Start the engine 2-3 times in succession (10-second intervals between each start), confirm the starter operates stably without overheating or abnormal noise.
Power-off OperationThe negative terminal of the battery must be disconnected throughout the installation process. Do not plug/unplug wiring harnesses or tighten bolts when the power is on to prevent short circuits that cause sparks, burn out the solenoid switch or battery, or even lead to electric shock hazards.Before reconnecting the negative battery terminal, ensure all connections are secure and no exposed wires are in contact with metal components to avoid short circuits at the moment of power-on.
Mechanical ProtectionHold the starter firmly when lifting it to prevent slipping and injury to hands or damage to engine components (e.g., oil pan, pipelines); do not release the hold until the mounting bolts are fully tightened.Clean oil stains and debris from the operation area to prevent slipping; avoid dropping tools into the engine compartment (e.g., flywheel housing) to prevent interference with operation.
Bolt Tightening RequirementsApply medium-strength thread locker (e.g., Loctite 243) to the mounting bolts, but do not over-apply (to prevent thread locker from entering the starter interior and corroding the coil).Tighten the mounting bolts in a diagonal sequence, with torque strictly controlled at 25-35N·m (refer to Mitsubishi's original specifications); insufficient torque may cause loosening due to vibration, while excessive torque may crack the mounting seat or strip the threads.The torque for the control wire terminal nut should be controlled at 8-12N·m; over-tightening will damage the terminal threads, while under-tightening will cause poor contact and overheating ablation.
Installation Positioning RequirementsUse only original matching gaskets (if provided); do not omit or replace with non-standard gaskets, otherwise the starter installation angle will be offset, leading to misalignment between the drive gear and flywheel ring gear, causing gear grinding, abnormal noise, or even damage to the ring gear.The drive gear end of the starter must face the flywheel ring gear; push it into the mounting seat smoothly without forced prying to avoid housing deformation or mounting hole misalignment.
Model MatchingThe 12V 1.9KW starter is only suitable for specified Mitsubishi gasoline engines (e.g., 4G63, 4G64 2.0L/2.4L models). Do not use it for diesel engines or models with mismatched displacement (diesel engines require higher-power starters; mixing will result in weak starting or motor burnout).Check the starter part number (original numbers usually start with M000Txxxxxx) before installation to confirm matching with the engine VIN code, avoiding mounting hole mismatch or electrical incompatibility due to model differences.
Wiring Harness MatchingThe power cable must use the original specification (≥6mm² copper core wire); do not replace with thinner wires, otherwise excessive resistance will cause insufficient starting voltage and overheating fusion of the wire.The control wiring harness must be connected securely with plugs locked in place to prevent loosening from vibration and no-start issues; organize the wiring harness away from high-temperature engine components (e.g., exhaust pipe, turbocharger) with a distance of ≥5cm to prevent aging and damage to the harness.
References：
Original maintenance manuals for corresponding Mitsubishi engines (e.g., manuals for models such as 4G63/4G64), which include core parameters like starter installation torque, mounting hole alignment, wiring harness connection specifications, as well as adaptability requirements for the flywheel ring gear and starter drive gear.
Original accessory specifications for Mitsubishi 12V 1.9KW starters (part numbers usually start with M000Txxxxxx), which mark exclusive requirements such as the use of installation gaskets and wiring terminal specifications.
General maintenance technical standards for automotive starters, such as industry-consensus content including the principle of diagonal bolt tightening, battery power-off operation procedures, and startup test intervals (≤5 seconds per start, interval ≥10 seconds).
Professional automotive maintenance textbooks and courseware (e.g., standard courseware for starter disassembly, assembly and maintenance), covering basic precautions such as safe operation, mechanical protection and fault prevention.
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