STARTER (for DENSO Made) INSPECTION


  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 be done within 3 to 5 seconds to prevent the coil from burning out.


    1. A01IS21E02

      Perform the pull-in test.


      1. Disconnect the field coil wire from terminal C.

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

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

    2. A01IRMCE01

      Perform the holding test.


      1. Maintain the battery connections of the pull-in test above, but disconnect the negative (-) lead from terminal C. Check that the pinion gear remains extended.

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

    3. A01IU0AE01

      Inspect the clutch pinion gear return.


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

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

    4. A01IOOXE01

      Perform the 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:
        6.5 N*m  { 66 kgf*cm, 57 in.*lbf }

      2. Clamp 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 out. Then measure the current.

        Standard current
        190 A or less at 11.5 V

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

  2. INSPECT STARTER ARMATURE ASSEMBLY


    1. A01INIYE04

      Inspect 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
        Commutator - Commutator Always Below 1 Ω

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

    2. A01IPNLE01

      Inspect 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 - Armature coil core Always 10 kΩ or higher

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

    3. A01IP3RE01

      Using a vernier caliper, measure the commutator diameter.

      Standard diameter
      35.0 mm (1.38 in.)
      Minimum diameter
      34.0 mm (1.34 in.)

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

    4. A01IRX5

      Check the commutator circle runout.


      1. Place the shaft of starter armature on V-blocks.

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

        Maximum commutator runout
        0.05 mm (0.00197 in.)

        If the runout is more than the maximum, replace the commutator assembly.

    5. A01IPA3E01

      Measure the undercut depth of the commutator.

      Standard undercut depth
      0.7 mm (0.0276 in.)
      Minimum undercut depth
      0.2 mm (0.00787 in.)

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

    6. 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.

  3. INSPECT STARTER YOKE ASSEMBLY


    1. A01IUGV

      Inspect the field 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 C wire - Brushes Always Below 1 Ω

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

    2. A01IMXP

      Check if the field coil is grounded.


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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Brushes - Starter yoke body Always 10 kΩ or higher

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

  4. INSPECT BRUSH


    1. A01ITRAE02

      Using a vernier caliper, measure the brush length.

      Standard length
      15 mm (0.591 in.)
      Minimum length
      9.0 mm (0.354 in.)

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

  5. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. A01ISN4E01

      Inspect the insulation.


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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Positive brush holder - Negative brush holder Always 10 kΩ or higher

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

    2. Inspect the load of the brush spring.


      1. A01IU7DE05

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

        Standard spring load
        22 to 28 N (2 to 3 kgf, 4.8 to 6.2 lbf)
        Minimum spring load
        12 N (1 kgf, 2.8 lbf)

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

  6. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY


    1. Check the gear teeth of the planet gears and starter center bearing clutch for wear or damage.

      If any planet gear is damaged, replace the planet gear assembly.

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

    2. A01ISFPE01

      Check the movement of the clutch pinion gear.


      1. 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.

  7. INSPECT MAGNET STARTER SWITCH ASSEMBLY


    1. A01IPCRE02
      Text in Illustration
      *1 Terminal 50
      *2 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.

    2. A01ISOAE02
      Text in Illustration
      *1 Terminal 50

      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 - Switch body Always Below 2 Ω

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