STARTER(for TMMF Made Cold Area Specification Vehicles) INSPECTION

PROCEDURE


  1. INSPECT STARTER ASSEMBLY

    Note

    Perform each of the following tests within 3 to 5 seconds.


    1. Perform pull-in test.


      1. Disconnect the field coil lead wire from terminal C.

      2. A01VLM8E02
        Text in Illustration
        *1 Terminal C
        *2 Terminal 50

        Connect the battery to the starter magnetic switch as shown in the illustration and check that the pinion gear is extended.

    2. A01VH1QE03
      Text in Illustration
      *1 Terminal C
      *2 Terminal 50

      Perform holding test.


      1. Check that the pinion gear does not return inward after the cable of terminal C is disconnected.

    3. A01VEYTE02
      Text in Illustration
      *1 Terminal C
      *2 Terminal 50

      Inspect the clutch pinion gear return.


      1. Move the pinion gear toward the armature.

    4. Perform the operation test without any load.


      1. Connect the field coil lead wire to terminal C.

        Torque:
        5.9 N*m  { 60 kgf*cm, 52 in.*lbf }

      2. Clamp the starter in a vise.

        Note

        Do not clamp the vise to tightly.

      3. A01VJ26E02
        Text in Illustration
        *1 Terminal 30
        *2 Terminal 50

        Connect the battery and ammeter to the starter as shown in the illustration.

      4. Check that the starter rotates smoothly and steadily with the clutch pinion gear extended. 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 11.5 V Below 190 A

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

  2. INSPECT MAGNET STARTER SWITCH ASSEMBLY


    1. A01VGJH

      Check the plunger.


      1. Install the plunger and spring onto the switch body.

      2. A01VIDY

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

        If necessary, replace the magnet starter switch assembly.

    2. A01VLJNE02
      Text in Illustration
      *1 Terminal 50
      *2 Terminal C

      Check the pull-in coil for an open circuit.


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

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

        If the standard is not met, replace the magnet starter switch assembly.

    3. A01VFGFE02
      Text in Illustration
      *1 Terminal 50
      *2 Switch Body

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


      1. Using an ohmmeter, measure the resistance between terminals 50 and the switch body.

        Standard Resistance
        Tester Connection Condition Specified Condition
        Terminal 50 - Switch body Always Below 1.5 Ω

        If the standard is not met, replace the magnet starter switch assembly.

  3. INSPECT STARTER ARMATURE ASSEMBLY


    1. A01VLGZE10
      Text in Illustration
      *1 Commutator

      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 - Segment Always Below 1 Ω

        If the standard is not met, replace the starter armature assembly.

    2. A01VKROE14
      Text in Illustration
      *1 Armature
      *2 Commutator

      Check the commutator for ground.


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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Commutator - Armature coil core Always 10 kΩ or higher

        If the standard is not met, replace the starter armature assembly.

    3. A01VLTS

      Check the appearance.

      If the surface is dirty or burnt, restore the surface with 400-grit sandpaper on a lathe.

    4. Check the commutator circuit for runout.


      1. Place the commutator on V-blocks.

      2. Using a dial indicator, measure the circle runout.

        Standard runout
        0.02 mm (0.0008 in.)
        Maximum runout
        0.05 mm (0.0020 in.)

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

    5. A01VE1B

      Using a vernier caliper, measure the commutator diameter.

      Standard diameter
      29 mm (1.142 in.)
      Minimum diameter
      28 mm (1.102 in.)

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

  4. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. Remove the claw of the spring, then remove the 4 brushes.

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

      Standard length
      15.5 mm (0.610 in.)
      Minimum length
      12 mm (0.472 in.)

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

      A01VIYJE10
      Text in Illustration
      *1 Brush *2 Spring
      *3 Length - -
    3. A01VDW2E13

      Check the brush holder.


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

        Standard resistance
        Tester Connection Specified Condition
        A - B 10 kΩ or higher
        A - C 10 kΩ or higher
        A - D Below 1 Ω
        B - C Below 1 Ω
        B - D 10 kΩ or higher
        C - D 10 kΩ or higher

        If the standard is not met, replace the starter brush holder assembly.

  5. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY


    1. Inspect the gear teeth on the planetary gear, internal gear and starter clutch for wear and damage.

      If damaged, replace the gear or clutch assembly. Also check the planetary gear for wear and damage.

    2. A01VG4ZE02
      Text in Illustration
      *a Free
      *b Lock

      Inspect the starter clutch.


      1. Rotate the clutch pinion gear clockwise and check that it turns freely. Try to rotate the clutch pinion gear counterclockwise and check that it locks.

        If necessary, replace the starter center bearing clutch sub-assembly.