STARTER(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 became 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. A00479Z

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

      2. A00482XC02
        *a Starter Body
        *b Terminal C
        *c Terminal 50
        *d Battery
        A0049LZ Moves outward

        Connect the battery to the repair service starter kit as shown in the illustration. Then check that the clutch pinion gear moves outward.

        If the clutch pinion gear does not move outward, replace the repair service starter kit.

    2. Perform a holding test.


      1. A0049W6C01
        *a Starter Body
        *b Terminal C
        *c Terminal 50
        *d Battery
        A0049LZ Disconnect

        Disconnect the negative (-) lead from terminal C with the condition specified in the pull-in test above being maintained. Check that the pinion gear remains out.

        If the clutch pinion gear returns inward, replace the repair service starter kit.

    3. Check return operation.


      1. A004AK4C01
        *a Starter Body
        *b Terminal C
        *c Terminal 50
        *d Battery

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

        If the clutch pinion gear does not move inward, replace the repair service starter kit.

    4. Perform a no-load performance test.


      1. A00479Z

        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 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. A0049X4C01
        *a Starter Body
        *b Terminal 50
        *c Terminal 30
        *d Probe
        *e Battery
        A0049LZ Rotates

        Connect the battery and a probe 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 operates smoothly and steadily with the pinion gear 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 11.5 V 90 A or less

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

  2. INSPECT STARTER ARMATURE ASSEMBLY

    Tech Tips

    If there is no continuity between any segments, replace the starter armature assembly.


    1. Check the commutator appearance.

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

    2. Check the commutator for an open circuit.


      1. A004A96C09
        *a Segment

        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. Check the commutator for a short circuit.


      1. A004A9OC09
        *a Segment
        *b Starter Armature Coil Core

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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Segment - Starter armature coil core Always 10 kΩ or higher

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

    4. A0047QIC12
      *a Length

      Using a vernier caliper, measure the commutator.

      Standard length
      3.1 mm (0.122 in.)
      Maximum length
      3.8 mm (0.150 in.)

      If the length is more than the maximum, replace the starter armature assembly.

  3. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. Check the brush length.


      1. A00492OC04
        *a Length

        Using a vernier caliper, measure the brush length.

        Standard length
        9.0 mm (0.354 in.)
        Minimum length
        4.0 mm (0.157 in.)

        If the length is less than the minimum, replace the starter commutator end frame assembly.

    2. Check the brush insulation.


      1. A004ACIC02
        *a Positive (+) Brush
        *b Negative (-) Brush

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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Positive (+) brush - Negative (-) brush Always 10 kΩ or higher

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

  4. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY


    1. Check the gear teeth on the planetary gears, and the internal gear and pinion gear of the starter center bearing clutch sub-assembly for wear or damage.

      If any of the gears is damaged, replace the starter center bearing clutch sub-assembly.

    2. Check the starter center bearing clutch pinion gear.


      1. A0048MKC09
        A0049LZ Free
        A004864 Lock

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

        If the result is not as specified, replace the starter center bearing clutch sub-assembly.

  5. INSPECT REPAIR SERVICE STARTER KIT


    1. Check the plunger.


      1. A004B6I

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

        If the result is not as specified, replace the repair service starter kit.

    2. Check the pull-in coil for an open circuit.


      1. A0046SNC13
        *a Terminal 50
        *b Terminal C

        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 repair service starter kit.

    3. Check the holding coil for an open circuit.


      1. A0046XBC13
        *a Terminal 50
        *b Magnet Switch Body

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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Terminal 50 - Magnet switch body Always Below 2 Ω

        If the result is not as specified, replace the repair service starter kit.