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 no-load performance test.


      1. A01KD30C05
        *a Starter Body

        Connect the positive (+) lead to terminal SL1.

      2. Connect the negative (-) lead to the starter body and check that the clutch pinion gear moves outward.

        Note

        If the positive (+) and negative (-) leads are connected incorrectly, the IC inside of the starter inrush current reduction relay will be damaged. Be sure to connect them correctly.

      3. A01KAL1C04
        *a Starter Body

        With the clutch pinion gear in the outward position, disconnect the negative (-) lead and check that the clutch pinion gear returns inward.

      4. A01KDBFC04
        *a Starter Body

        Connect the positive (+) lead to terminal SL2 of the connector and the negative (-) lead to the starter body. Check that a clicking sound is heard from the starter motor.

      5. 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.

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

        A01KCT4C06
        *a Starter Body *b Terminal 30
        *c AC/DC 400 A Probe - -

      7. Connect terminal SL2 and measure the current after the ammeter reading has stabilized.

        Standard Current
        Tester Connection Condition Specified Condition
        Battery positive (+) terminal - Terminal 30 - Terminal SL2 11.5 V Below 130 A

        Tech Tips

        If the starter assembly does not operate when terminal SL2 is connected, perform the following steps (*1) through (*5).

      8. A01KDASC02
        *1 Wire Harness
        *a Terminal C
        *b Terminal M
        *c Lead Wire

        Disconnect the repair service starter kit connector. (*1)

      9. Remove the nut and disconnect the wire harness from terminal C. (*2)

      10. Remove the nut and disconnect the lead wire from terminal M. (*3)

      11. Connect the lead wire to terminal C with the nut. (*4)

        Torque:
        9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

      12. Connect the battery and an ammeter to the starter assembly as shown in the illustration. (*5)

        A01KDH5C02
        *a Starter Body *b Terminal 30
        *c AC/DC 400 A Probe - -

        If the starter assembly does not operate, replace the repair service starter kit.

  2. INSPECT STARTER ARMATURE ASSEMBLY


    1. A01KDRRC01
      *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. A01KAPUC01
      *a Segment
      *b Starter Armature Core

      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 - Starter armature 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, replace the starter armature assembly.

    4. A01KC1V

      Check the commutator for runout.


      1. Place the commutator on V-blocks.

      2. Using a dial indicator, measure the runout.

        Maximum runout
        0.05 mm (0.00197 in.)

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

    5. A01KCHL

      Using a vernier caliper, measure the commutator diameter.

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

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

    6. A01KB93

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

      Standard undercut depth
      0.7 mm (convex part) (0.0276 in.)
      Minimum undercut depth
      0.4 mm (convex part) (0.0157 in.)

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

  3. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. A01KDOSC04
      *a Length

      Check the brush length.


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

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

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

    2. A01KBAXN11

      Check the starter brush holder assembly resistance.


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

        Standard Resistance
        Tester Connection Condition Specified Condition

        A - B

        A - C

        B - D

        C - D

        		 Always 10 kΩ or higher

        A - D

        B - C

        		 Below 1 Ω

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

    3. Check the brush spring load.


      1. A01KDT6

        Take a pull scale reading the instant the brush spring separates from the brush.

        Standard spring load
        22 to 27 N (2 to 3 kgf, 4.9 to 6.1 lbf)
        Minimum spring load
        14 N (1 kgf, 3.1 lbf)

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

  4. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY

    A01KC7RC03
    *a Free
    *b Lock

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

        If the clutch pinion gear does not operate as specified, replace the starter center bearing clutch sub-assembly.

  5. INSPECT REPAIR SERVICE STARTER KIT

    A01KCVV

    1. Check the plunger.


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

        Note


        • To avoid damaging the inside of the magnet switch, do not release the plunger quickly.

        • Do not drop the plunger.

        If necessary, replace the repair service starter kit.

    2. A01KAV5C02
      *a Magnet Switch Body

      Check the repair service starter kit resistance.


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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Terminal SL1 - Magnet switch body Always Below 1 Ω
        Terminal SL2 - Magnet switch body Below 2 Ω

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