Starter Repair Procedures

Removal

1. 1
   Turn the ignition switch OFF and disconnect the negative (-) battery cable.
2. 2
   Remove the right exhaust manifold. (Refer to Engine Mechanical System - "Exhaust Manifold")
3. 3
   Remove the engine support bracket (A) after loosening the mounting bolt and nut.

   

4. 4
   Disconnect the starter connector (A) and cable (B) from terminal "B".

   

5. 5
   Remove the starter (B) by unscrewing the mounting bolts (A).

   

Installation

1. Install in the reverse order of removal. Starter mounting bolt: 49.0~64 N·m Starter cover mounting bolt: 8.8~13.7 N·m Engine mounting insulator upper nut: 63.7~83 N·m

Disassembly

1. 1
   Disconnect terminal M from the magnetic switch assembly.

   

2. 2
   Loosen the 3 screws (A) and disconnect the magnetic switch assembly (B).

   

3. 3
   Loosen the through bolts (A).

   

4. 4
   Remove the brush holder assembly (A), the fork (B) and the armature (C).

   

5. 5
   Remove the shield (A).

   

6. 6
   Remove the lever plate (A) and the lever packing (B).

   

7. 7
   Disconnect the planetary gear (A).

   

8. 8
   Disconnect the planetary shaft assembly (A) and the lever (B).

   

9. 9
   Press the snap ring (A) using the socket (B).

   

10. 10
    Remove the plug (A) using pliers (B).

    

11. 11
    Disconnect the snap ring (A), overrunning clutch (B), internal gear (C) and planetary shaft (D).

    

12. 12
    For assembly, repeat the disassembly procedure in reverse order.

    Using a suitable puller (A), slide the overrunning clutch snap ring (B) onto the stopper (C).

    

Inspection

1. 1
   Disconnect the lead wire from the M terminal of the magnetic switch.
2. 2
   Connect the battery as shown in the illustration. If the starter pinion gear moves out, it is in good condition.

   To prevent damage to the starter, do not keep the battery connected for more than 10 seconds.

   

3. 3
   Disconnect the battery from the M terminal. If the pinion gear does not retract, the hold-in coil is operating correctly.

   To prevent damage to the starter, do not keep the battery connected for more than 10 seconds.

   

4. 4
   Also disconnect the battery from the housing. If the pinion gear retracts immediately, it is operating correctly.

   To prevent damage to the starter, do not keep the battery connected for more than 10 seconds.

   

5. 5
   Place the starter in a vise with soft jaws and connect a fully charged 12-volt battery to the starter as follows.
6. 6
   Connect a test ammeter (150 A scale) and carbon pile rheostat as shown in the illustration.
7. 7
   Connect a voltmeter (15-volt scale) to the starter.

   

8. 8
   Turn the carbon pile to the OFF position.
9. 9
   Connect the battery cable from the negative battery terminal to the starter housing.
10. 10
    Adjust until the battery voltage shown on the voltmeter reads 11 volts.
11. 11
    Make sure the maximum current is within specification and that the starter rotates smoothly and freely.

    Items	Specification
    Current (Max.)	105 A
    Speed (Min.)	2800 rpm

12. 12
    Remove the starter motor.
13. 13
    Disassemble the starter and separate the armature from the starter.
14. 14
    Inspect the armature contacting the permanent magnet for wear or damage. If there is wear or damage, replace the armature.

    

15. 15
    Inspect the commutator surface (A). If the surface is dirty or burnt, correct the surface to specification using abrasive material or #500 or #600 sandpaper (B).

    

16. 16
    Measure the commutator runout (A).

    A.	If the commutator runout is within the limit, check the commutator for carbon dust or brass chips between the segments.

    B.	If the commutator runout exceeds the limit, replace the armature.

    Commutator Runout Standard (new): 0.05 mm (0.0019 in.) max. Service limit: 0.08 mm (0.0031 in.)

    

17. 17
    Check the undercut depth of the mica (A). If the mica is too high (B), undercut the mica with a hacksaw to the correct depth. Remove all mica (C) between the commutator segments. The undercut must not be too shallow, too narrow or V-shaped (D). Commutator mica undercut depth Standard (new): 0.7 mm (0.0276 in.) Limit: 0.2 mm (0.0079 in.)

    

18. 18
    Check the continuity between the commutator segments. If there is an open circuit between any segments, replace the armature.

    

19. 19
    Using an ohmmeter, check that there is no continuity between the commutator (A) and the armature coil core (B), and between the commutator and the armature shaft (C). If there is continuity, replace the armature.

    

    

20. 20
    Make sure there is no continuity between the (+) brush holder (A) and the (-) plate (B). If there is continuity, replace the brush holder assembly.

    

21. 21
    Slide the overrunning clutch along the shaft. Replace it if it does not slide smoothly.
22. 22
    Rotate the overrunning clutch in both directions. It should lock in one direction and rotate smoothly in the other. If it does not lock in either direction, or locks in both directions, replace it.

    

23. 23
    If the starter pinion gear is worn or damaged, replace the overrunning clutch assembly (the pinion gear is not sold separately). Inspect the condition of the flywheel ring gear or torque converter drive plate if the starter pinion gear teeth are damaged.

Cleaning

1. 1
   Do not immerse parts in cleaning solvent. Immersing the yoke assembly and/or armature may damage the insulation. Wipe these parts with a cloth only.
2. 2
   Do not immerse drive parts in cleaning solvent. The overrunning clutch is pre-lubricated at the factory, and the clutch grease will be washed off by solvent.
3. 3
   Clean the drive parts with a brush moistened with cleaning solvent, then wipe them with a dry cloth.