STARTER(w/ Stop And Start System) INSPECTION

PROCEDURE


  1. INSPECT STARTER ASSEMBLY

    CAUTION:

    As a large electric current passes through the cable during this inspection, a thick cable must be used. If not, the cable may become hot and cause injury.

    Note

    Perform each of the following tests within 3 to 5 seconds to prevent the coil from burning out.


    1. Perform a pull-in test.


      1. A01VLUK

        Remove the nut to disconnect the lead wire from terminal C.

      2. A01VH1GE01
        Text in Illustration
        *a Starter Body
        *b Terminal 45
        *c Terminal 50

        Connect the battery to the magnet starter switch assembly as shown in the illustration. Check that the clutch pinion gear moves outward.

        If the clutch pinion gear does not move outward, replace the starter assembly.

    2. Perform a holding test.


      1. A01VHVCE02
        Text in Illustration
        *a Starter Body
        *b Terminal 45
        *c Terminal 50

        Check that the pinion gear does not return inward after the lead is disconnected from the terminal C.

        If the clutch pinion gear returns inward, replace the starter assembly.

    3. Check return operation.


      1. A01VDZUE01
        Text in Illustration
        *a Starter Body
        *b Terminal 45
        *c Terminal 50

        Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear moves inward.

        If the clutch pinion gear does not move inward, replace the starter assembly.

    4. Perform a no-load performance test.


      1. A01VLUK

        Connect the lead wire to terminal C with the nut.

        Torque:
        8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

      2. Hold the starter assembly in a vise between aluminum plates.

        Note

        Ensure that the starter assembly is secured in the vise to prevent it from falling out.

      3. A01VDN5E02
        Text in Illustration
        *a Starter Body
        *b Terminal 30
        *c Terminal 50
        *d Probe

        Connect the battery and a prove to the starter assembly as shown in the illustration.

        Note

        Do not allow any lead to get caught as the pinion gear operates.

      4. Check that the starter assembly operates smoothly and steadily while the clutch pinion gear is moving outward.

        Measure the current according to the value(s) in the table below.

        Standard Current
        Tester Connection Condition Specified Condition
        Battery positive terminal - Terminal 30 - Terminal 50 12 V Below 60 A

        If the result is not as specified, repair or replace the starter assembly.

  2. INSPECT STARTER ARMATURE ASSEMBLY


    1. A01VDIME01
      Text in Illustration
      *a Segment
      *b Starter Armature Assembly Coil Core

      Check the commutator for an open circuit.


      1. Measure the resistance according to the value(s) in the table below.

        Standard Resistance
        Tester Connection Condition Specified Condition
        Segment - Starter Armature Assembly Coil Core Always 10 kΩ or higher

        If the result is not as specified, replace the starter armature assembly.

    2. A01VFZQE01
      Text in Illustration
      *a Segment

      Check the commutator for a short circuit.


      1. Measure the resistance according to the value(s) in the table below.

        Standard Resistance
        Tester Connection Condition Specified Condition
        Segment - Segment Always Below 1 Ω

        If the result is not as specified, replace the starter armature assembly.

    3. A01VGZ6

      Check the commutator circumference runout.


      1. Place the commutator on V-blocks.

      2. Using a dial indicator, measure the runout.

        Maximum runout
        0.4 mm (0.0157 in.)

        If the runout is greater than the maximum, replace the starter armature assembly.

    4. A01VGLFE01
      Text in Illustration
      *a Diameter

      Using a vernier caliper, measure the commutator diameter.

      Standard diameter
      28 mm (1.1024 in.)
      Minimum diameter
      27 mm (1.0630 in.)

      If the diameter is less than the minimum, replace the starter armature assembly.

    5. A01VH7YE02
      Text in Illustration
      *a Undercut Depth

      Using a vernier caliper, measure the undercut depth of the commutator.

      Standard undercut depth
      0.6 mm (0.0236 in.)
      Minimum undercut depth
      0.2 mm (0.00787 in.)

      If the undercut depth is less than the minimum, adjust it with a hacksaw blade.

  3. INSPECT STARTER YOKE ASSEMBLY


    1. A01VECGE02
      Text in Illustration
      *a Brush
      *b Wire Harness

      Check the starter yoke assembly for an open circuits.


      1. Measure the resistance according to the value(s) in the table below.

        Standard Resistance
        Tester Connection Condition Specified Condition
        Wire harness - Brush leads (+) Always Below 1 Ω

        If the result is not as specified, replace the starter yoke assembly.

    2. A01VHULE02
      Text in Illustration
      *a Brush
      *b Starter Yoke Body

      Check the starter yoke assembly for ground.


      1. Measure the resistance according to the value(s) in the table below.

        Standard Resistance
        Tester Connection Condition Specified Condition
        Starter yoke body- Brush leads (+) Always 10 kΩ or higher

        If the result is not as specified, replace the starter yoke assembly.

    3. A01VEUME01
      Text in Illustration
      *a Length

      Check the brush length.


      1. Using a vernier caliper, measure the brush length.

        Standard length
        10 mm (0.3937 in.)
        Minimum length
        6 mm (0.2362 in.)

        If the length is less than the minimum, replace the starter yoke assembly.

    4. Check the brush for an open circuits.


      1. A01VL1GE03

        Measure the resistance according to the value(s) in the table below.

        Standard Resistance
        Tester Connection Condition Specified Condition

        A - B

        A - D

        B - C

        C - D

        		 Always 10 kΩ or higher

        A - C

        B - D

        		 Below 1 Ω

        If the result is not as specified, replace the starter yoke assembly.

  4. INSPECT STARTER CLUTCH SUB-ASSEMBLY


    1. A01VGVAE01
      Text in Illustration
      *a Free
      *b Lock

      Check the starter clutch sub-assembly.


      1. Hold the starter clutch sub-assembly and rotate the pinion gear clockwise, and check that it turns freely. Try to rotate the pinion gear counterclockwise and check that it locks.

        If necessary, replace the starter clutch sub-assembly.

  5. INSPECT MAGNET STARTER SWITCH ASSEMBLY


    1. Check the plunger.


      1. A01VI8N

        Install the starter pinion drive lever and return spring to the magnet starter switch assembly.

      2. A01VH7I

        Push in the plunger and check that it returns quickly to its original position.

        If the plunger does not operate as specified, replace the magnet starter switch assembly.

    2. A01VI1VE02
      Text in Illustration
      *a Terminal 50
      *b Terminal 45

      Check the pull-in coil for an open circuit.


      1. Using an ohmmeter, check the resistance between terminals 50 and 45.

        Standard Resistance
        Tester Connection Condition Specified Condition
        Terminal 50 - Terminal 45 Always Below 1 Ω

        If the result is not as specified, replace the magnet starter switch assembly.

    3. A01VDVTE02
      Text in Illustration
      *a Terminal 50
      *b Magnet Starter Switch Assembly Body

      Check whether the holding coil has an open circuit.


      1. Using an ohmmeter, check the resistance between terminal 50 and magnet starter switch assembly body.

        Standard Resistance
        Tester Connection Condition Specified Condition
        Terminal 50 - Magnet Starter Switch assembly body Always Below 2 Ω

        If the result is not as specified, replace the magnet starter switch assembly.