STARTER (for VALEO 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. Perform the pull-in test.


      1. Disconnect the lead wire from terminal C.

      2. A01IT85E01

        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. A01IRQ0E01

      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. A01INWZE01

      Check 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. A01ISPKE01

      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:
        9.5 N*m  { 97 kgf*cm, 84 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
        145 A or less at 11.5 V

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

  2. INSPECT STARTER ARMATURE ASSEMBLY


    1. A01IU2B

      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. A01IUNJ

      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. A01IS0B

      Using a vernier caliper, measure the commutator diameter.

      Standard diameter
      30.0 mm (1.18 in.)
      Minimum diameter
      28.5 mm (1.12 in.)

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

    4. A01IQ7V

      Check the commutator circle runout.


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

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

        Standard runout
        0.02 mm (0.000787 in.)
        Maximum runout
        0.05 mm (0.00197 in.)

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

    5. 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. A01IN8B

      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. A01IPIO

      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
        Terminal C wire - Starter yoke body Always 10 kΩ or higher

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

  4. INSPECT STARTER BRUSH


    1. A01INYBE01

      Using a vernier caliper, measure the brush length.

      Standard length
      13.7 mm (0.539 in.)
      Minimum length
      6.0 mm (0.236 in.)

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

  5. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. A01IRC3E01

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      A - B Always 10 kΩ or higher
      A - C 10 kΩ or higher
      A - D 10 kΩ or higher
      B - C 10 kΩ or higher
      B - D Below 1 Ω
      C - D 10 kΩ or higher

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

  6. INSPECT STARTER CLUTCH SUB-ASSEMBLY


    1. A01IPDKE01

      Check the starter clutch operation.


      1. Hold the clutch and bearing with one hand and turn the shaft with the other. Check that the inner sleeve turns easily in the "free" direction but cannot turn in the "lock" direction as shown in the illustration.

        If the starter clutch sub-assembly does not operate as specified, replace the starter clutch sub-assembly.

  7. INSPECT MAGNET STARTER SWITCH ASSEMBLY


    1. Check the plunger.


      1. A01IR6U

        Install the starter drive lever pin to the magnet starter switch.

      2. A01IQSJ

        Push in the starter drive lever pin and check that it returns quickly to its original position.

        If the magnet starter switch assembly does not operate as specified, replace the magnet starter switch assembly.

    2. A01IUMKE01
      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 0.3 Ω

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

    3. A01ITL4E01
      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 1 Ω

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