STARTER(for Automatic Transmission) 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

    The following tests must each be performed within 3 to 5 seconds to prevent the coil from burning out.


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

    2. Perform a pull-in test.


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

      2. A004ISUE03
        Text in Illustration
        *1 Body
        *2 Terminal 50
        *3 Terminal C

        Connect the battery to the starter as shown in the illustration. Check that the clutch pinion gear extends.

        If the clutch pinion gear does not move, inspect the magnet starter switch assembly. If the magnet starter switch assembly is not as specified, replace it.

    3. Perform a holding test.


      1. A004H7FE03
        Text in Illustration
        *1 Body
        *2 Terminal 50
        *3 Terminal C

        Disconnect the negative (-) terminal lead from terminal C while the conditions specified in the pull-in test above are maintained. Check that the pinion gear remains out.

        If the clutch pinion gear returns inward, inspect the magnet starter switch assembly. If the magnet starter switch assembly is not as specified, replace it.

    4. Inspect the clutch pinion gear return.


      1. A004KNME03
        Text in Illustration
        *1 Body
        *2 Terminal 50
        *3 Terminal C

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

        If the clutch pinion gear does not return inward, inspect the magnet starter switch assembly. If the magnet starter switch assembly is not as specified, replace it.

    5. Perform an operation test without load.


      1. Connect the lead wire to terminal C with the nut.

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      2. A004KU9E03
        Text in Illustration
        *1 Terminal 50
        *2 Terminal 30
        *3 Ammeter

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

      3. Check that the starter rotates smoothly and steadily while the clutch pinion gear is extended. Then measure the current.

        Standard Current
        Tester Connection Condition Specified Condition
        Battery positive terminal - Terminal 30 - Terminal 50 11.5 V Below 90 A

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

        Tech Tips

        Inspect the starter armature assembly, starter commutator end frame assembly and magnet starter switch assembly. If there is a malfunction, replace the part and perform again this test.

  2. INSPECT STARTER ARMATURE ASSEMBLY


    1. Check the commutator for dirt and/or burns on the surface.

      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 commutator for an open circuit.


      1. A004J92E02
        Text in Illustration
        *1 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. Inspect the commutator for short circuits.


      1. A004HDBE16
        Text in Illustration
        *1 Segment
        *2 Coil Core

        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.

    4. Check the commutator for signs of seizure or stepped wear caused by roughness of the surface. If there is light wear, use sandpaper to repair.

    5. A004JA1E04
      Text in Illustration
      *1 Dial Gauge
      *2 V-block

      Check for runout on the commutator. If excessive, replace the armature.

      Standard runout
      0.02 mm (0.0008 in.)
      Maximum runout
      0.05 mm (0.002 in.)

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

    6. A004IQBE04
      Text in Illustration
      *a Diameter

      Using vernier caliper, measure the commutator diameter.

      Standard diameter
      29 mm (1.1417 in.)
      Minimum diameter
      28 mm (1.1024 in.)

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

    7. A004IRP

      Using vernier caliper, measure the under cut depth of the segment. If it is not within the standard, replace the starter armature assembly.

      Standard depth
      0.7 mm (0.0276 in.)
      Minimum depth
      0.2 mm (0.0079 in.)

  3. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. A004JTHE02
      Text in Illustration
      *a Length

      Using a vernier caliper, measure the brush length.

      Standard length
      14.4 mm (0.5669 in.)
      Minimum length
      9.0 mm (0.3543 in.)

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

    2. A004JXDE16

      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

      		 Always Below 1 Ω

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

  4. INSPECT MAGNET STARTER SWITCH ASSEMBLY


    1. Check the plunger.


      1. A004IRO

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

        If necessary, replace the magnet starter switch assembly.

    2. Inspect the pull-in coil.


      1. A004K0OE02
        Text in Illustration
        *1 Terminal C
        *2 Terminal 50

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

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

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

    3. Inspect the holding coil.


      1. A004JKZE02
        Text in Illustration
        *1 Terminal 50
        *2 Switch Body

        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.