STARTER(w/o Stop and Start System for Cold Area Specification Vehicles) 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. A01VFXU

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

      2. A01VDSUE04
        Text in Illustration
        *a Terminal C
        *b Terminal 50
        *c Starter Body

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

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

    2. A01VF25E04
      Text in Illustration
      *a Terminal C
      *b Terminal 50
      *c Starter Body

      Perform a holding test.


      1. Disconnect the lead from terminal C. Check that the clutch pinion gear does not move inward.

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

    3. A01VK9LE04
      Text in Illustration
      *a Terminal C
      *b Terminal 50
      *c Starter Body

      Check return operation.


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

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

    4. A01VFXU

      Perform a no-load performance test.


      1. Connect the lead wire to terminal C with the nut. Make sure that the lead wire is not grounded.

        Torque:
        10 N*m  { 102 kgf*cm, 7.4 ft.*lbf }

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

        Note

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

      3. A01VGPBE01
        Text in Illustration
        *a Terminal 30
        *b Terminal 50
        *c Starter Body
        *d Probe

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

        Note

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

      4. Check that the starter rotates smoothly and steadily with the clutch pinion gear moved 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 11.5 V Below 150 A

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

  2. INSPECT MAGNET STARTER SWITCH ASSEMBLY


    1. Check the plunger.


      1. A01VHAX

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

        If the plunger does not return, replace the magnet starter switch assembly.

    2. A01VIQ0E03
      Text in Illustration
      *a Terminal 50
      *b 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 result is not as specified, replace the magnet starter switch assembly.

    3. A01VFHIE04
      Text in Illustration
      *a Terminal 50
      *b Magnet Starter Switch Assembly Body

      Check the holding 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 - Magnet starter switch assembly body Always Below 2 Ω

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

  3. INSPECT STARTER ARMATURE ASSEMBLY


    1. A01VLGZE10
      Text in Illustration
      *a Segment

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

    2. A01VFKEE01
      Text in Illustration
      *a Coil Core
      *b Commutator

      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
        Commutator -Ccoil core Always 10 kΩ or higher

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

    3. Check the commutator appearance.

      If the surface is dirty or burnt, restore it with sandpaper (No. 400) or a lathe.

    4. A01VHO2E03
      Text in Illustration
      *a Starter Armature Assembly shaft

      Check the commutator for runout.


      1. Place the armature shaft on V-blocks.

      2. Using a dial indicator, measure the runout.

        Maximum runout
        0.05 mm (0.00197 in.)

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

    5. A01VFL5E01
      Text in Illustration
      *a Diameter

      Using a vernier caliper, measure the commutator diameter.

      Standard diameter
      29 mm (1.14 in.) (at convex part)
      Minimum diameter
      28 mm (1.10 in.) (at convex part)

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

    6. A01VLA1E06
      Text in Illustration
      *a Undercut Depth

      Check that the undercut portion between the segments is free of foreign matter and measure its depth.

      Standard undercut depth
      0.4 mm (0.0157 in.) (at convex part)
      Minimum undercut depth
      0.2 mm (0.00787 in.) (at convex part)

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

  4. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. Check the brush length.


      1. A01VFNLE01
        Text in Illustration
        *a Length

        Using a vernier caliper, measure the brush length.

        Standard length
        14.4 mm (0.567 in.)
        Minimum length
        9.0 mm (0.354 in.) (at convex part)

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

    2. Check the starter brush holder assembly resistance.


      1. A01VEVLE02

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

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

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

    3. Inspect the load of the brush spring.


      1. A01VHCPE01
        Text in Illustration
        *a Brush
        *b Brush Spring

        Take the pull scale reading immediately after the brush spring separates from the brush.

        Standard spring installed load
        22 to 27 N (2 to 3 kgf, 5.0 to 6.1 lbf)
        Minimum spring installed load
        14 N (1 kgf, 3.1 lbf)

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

  5. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY


    1. Inspect the gear teeth of the planetary gears and internal gear of the starter center bearing clutch sub-assembly for wear and damage.

      If worn or damaged, replace the planetary gears or starter center bearing clutch sub-assembly. Also check the planetary gears for wear and damage.

    2. A01VJN9E05
      Text in Illustration
      *a Free
      *b Lock

      Check the movement of the clutch pinion gear.


      1. While holding the starter center bearing clutch sub-assembly, rotate the clutch pinion gear clockwise and check that it turns freely.

      2. Try to rotate the clutch pinion gear counterclockwise and check that it locks.

        If the clutch pinion gear cannot be turned clockwise smoothly, or does not lock in the counterclockwise direction, replace the starter center bearing clutch sub-assembly.