STARTER (for 2.2 kW Type Denso Made) INSPECTION


  1. INSPECT STARTER ASSEMBLY

    A01E16OE01

    CAUTION:

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


    1. Perform pull-in test.


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

      2. 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, replace the magnet starter switch assembly.

        A01DZZCE01

    2. Perform holding test.


      1. 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.

        A01DVIWE01

    3. Inspect clutch pinion gear return.


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

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

        A01DX6KE01

    4. Perform the operation test without load.


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

        Torque:
        5.9 N*m  { 60 kgf*cm, 52 in.*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.

        A01DV6UE01

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

        Standard current
        120 A or less at 11.5 V

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

  2. INSPECT STARTER ARMATURE ASSEMBLY


    1. Measure the resistance.


      1. A01E2ESE01

        Measure the resistance between the segments of the commutator.

        Standard resistance
        Below 1 Ω

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

      2. A01E0FQE01

        Measure the resistance between a segment of the commutator and the armature coil core.

        Standard resistance
        10 kΩ or higher

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

    2. A01DVU8

      Inspect circle runout.


      1. Place the armature on V-blocks.

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

        Maximum circle runout
        0.05 mm (0.0020 in.)

        If the circle runout is greater than the maximum, correct with sandpaper (#400) or replace the armature assembly.

    3. A01E2VA

      Using a vernier caliper, measure the commutator diameter.

      Standard commutator diameter
      35.0 mm (1.378 in.)
      Minimum commutator diameter
      34.0 mm (1.339 in.)

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

    4. A01E20M

      Measure the undercut depth of the commutator.

      Standard undercut depth
      0.7 mm (0.028 in.)
      Minimum undercut depth
      0.2 mm (0.008 in.)

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

    5. Inspect the armature bearings.


      1. Check that the armature bearings rotate smoothly.

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

  3. INSPECT STARTER YOKE ASSEMBLY


    1. A01E0BZE01

      Inspect the field coil for an open circuit.


      1. Measure the resistance between the lead wire and field coil brush lead.

        Standard resistance
        Below 1 Ω

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

    2. A01DWGFE01

      Inspect the ground.


      1. Measure the resistance between the lead wire and starter yoke body, and between the brushes and starter yoke body.

        Standard resistance
        10 kΩ or higher

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

  4. INSPECT BRUSH


    1. A01E2O9E01

      Using a vernier caliper, measure the brush length.

      Standard length
      16.5 mm (0.650 in.)
      Minimum length
      9.0 mm (0.354 in.)

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

  5. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. A01DZXP

      Inspect the brush insulation.


      1. Using an ohmmeter, measure the resistance between the positive and negative brush holders.

        Standard resistance
        10 kΩ or higher

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

    2. A01E1KQ

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

      Standard spring load
      26.5 to 32.3 N (2.7 to 3.3 kgf, 5.9 to 7.3 lbf)
      Minimum spring load
      17.6 N (1.8 kgf, 4.0 lbf)

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

  6. INSPECT STARTER CLUTCH SUB-ASSEMBLY


    1. A01DX5QE01

      Rotate the pinion gear clockwise and check that it turns freely. Try to rotate the pinion gear counterclockwise and check that it locks.

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

  7. INSPECT MAGNET STARTER SWITCH ASSEMBLY


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


      1. A01DV6NE01

        Measure the resistance between terminal 50 and terminal C.

        Standard resistance
        Below 1 Ω

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

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


      1. A01DZ3LE01

        Measure the resistance between terminal 50 and the switch body.

        Standard resistance
        Below 2 Ω

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