STARTER (for AWD) INSPECTION


  1. INSPECT STARTER ASSEMBLY

    CAUTION:

    As a large electric current passes through the cable during this inspection, a thick cable must be used. Otherwise, the cable may become hot and cause injury.

    Note

    These tests must be performed within 3 to 5 seconds to avoid burning out the coil.


    1. Perform a pull-in test.


      1. Remove the nut, and then disconnect the lead wire from terminal C.

      2. A01GJJ5E01
        Text in Illustration
        *1 Terminal 50
        *2 Terminal C

        Connect the battery to the magnet starter switch 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 magnet starter switch assembly.

    2. Perform a holding test.


      1. A01GKPJE01
        Text in Illustration
        *1 Terminal C
        A01GKOV Disconnect

        When the battery is connected as above with the clutch pinion gear out, disconnect the negative (-) lead from terminal C. Check that the pinion gear remains out.

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

    3. Inspect the clutch pinion gear return.


      1. A01GMUR

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

        Text in Illustration
        A01GKOV Disconnect

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

    4. Perform an operation test without load.


      1. A01GIG9E01
        Text in Illustration
        *1 Terminal 50
        *2 Terminal 30

        Connect the lead wire to terminal C with the nut.

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      2. Mount the starter in a vise between aluminum plates.

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

      4. Check that the starter rotates smoothly and steadily while the pinion gear is moving outward. Then measure the current.

        Standard current
        150 A or less at 11.5 V

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

  2. INSPECT MAGNET STARTER SWITCH ASSEMBLY


    1. Check the operation.


      1. A01GMTP

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

        If necessary, replace the magnet starter switch assembly.

    2. Check if the pull-in coil has an open circuit.


      1. A01GNFSE01
        Text in Illustration
        *1 Terminal 50
        *2 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 magnet starter switch assembly.

    3. Check if the holding coil has an open circuit.


      1. A01GM8WE01
        Text in Illustration
        *1 Terminal 50

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

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

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

  3. INSPECT STARTER ARMATURE ASSEMBLY


    1. Check the surface of the commutator for dirt and burns.

      If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe. If necessary, replace the starter armature assembly.

    2. Inspect the resistance of the commutator.


      1. A01GJI8

        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. A01GJFT

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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Segment - Coil core Always 10 kΩ or higher

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

    3. Check the commutator circle runout.


      1. A01GJUE

        Place the armature shaft on V-blocks.

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

        Maximum runout
        0.05 mm (0.00197 in.)

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

    4. A01GNIG

      Using a vernier caliper, measure the commutator diameter.

      Standard diameter
      29.0 mm (1.14 in.)
      Minimum diameter
      28.0 mm (1.10 in.)

      Tech Tips

      Be sure to measure the commutator diameter at the ridges.

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

    5. A01GK2HE01

      Check that the undercut portion is clean and free of foreign matter. Smooth out the edge.

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

      Tech Tips

      Be sure to measure the commutator undercut depth at a cutout.

      If the undercut depth is less than the minimum, increase the depth using a hacksaw blade.

  4. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. A01GIB2

      Using a vernier caliper, measure the brush length.

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

      Tech Tips

      Be sure to measure the brush lengths at the protrusions.

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

    2. Inspect the load of the brush spring.


      1. A01GJCDE13
        Text in Illustration
        *1 Brush
        *2 Brush Spring

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

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

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

  5. 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 for wear or damage.

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

    2. A01GMHM

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

      Text in Illustration
      A01GKOV Free
      A01GNZA Lock

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