Starter Inspection

Starter Solenoid 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 pops out, the starter is operating normally.

   

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

   

4. 4
   Disconnect the battery from the housing as well. If the pinion retracts immediately, the starter is operating normally.

   

No-Load Test

1. 1
   Place the starter in a vise with soft jaws and connect a fully charged 12-volt battery to the starter as follows.
2. 2
   Connect a test ammeter (150 A scale) and carbon pile rheostat as shown in the illustration.
3. 3
   Connect a voltmeter (15-volt scale) to the starter.

   

4. 4
   Turn the carbon pile to the OFF position.
5. 5
   Connect the battery cable from the battery negative terminal to the starter housing.
6. 6
   Adjust until the battery voltage shown on the voltmeter reads 11 volts.
7. 7
   Make sure that the maximum current is within specification and that the starter rotates smoothly and freely.

   Items	Current (Max.)	Speed (Min.)
   Non-ISG Type	95 A	2400 rpm

Armature

1. 1
   Remove the starter motor.
2. 2
   Disassemble the starter as shown at the beginning of this procedure.
3. 3
   Inspect the armature for wear or damage from contact with the permanent magnet. If wear or damage is found, replace the armature.

   

4. 4
   Inspect the commutator surface (A). If the surface is dirty or burnt, resurface it with sandpaper or on a lathe according to the following specifications, or polish with #500 or #600 sandpaper (B).

   

5. 5
   Check the commutator diameter. If the diameter is below the service limit, replace the armature. Commutator diameter Standard (new): 29.4 mm (1.1575 in) Service limit: 28.8 mm (1.1339 in)

   

6. 6
   Measure the commutator runout (A).

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

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

   Commutator runout Standard (new): 0.05 mm (0.0020 in.) max. Service limit: 0.10 mm (0.0039 in.) max.

   

7. 7
   Check the mica undercut depth (A). If the mica is too high (B), undercut the mica with a hacksaw to the correct depth. Cut away 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): 0.5 mm (0.0197 in) Limit: 0.2 mm (0.0079 in)

   

8. 8
   Check for continuity between the commutator segments. If there is an open circuit between any segments, replace the armature.

   

9. 9
   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.

   

Starter Brush

1. Replace brushes that are worn or contaminated with oil. Brush length Standard: 12.3 mm (0.4843 in.) Service limit: 5.5 mm (0.2165 in.)

   

Starter Brush Holder

1. Check that there is no continuity between the (+) brush holder (A) and the (-) plate (B). If there is continuity, replace the brush holder assembly.

   

Overrunning Clutch

1. 1
   Slide the overrunning clutch along the shaft. Replace it if it does not slide smoothly.
2. 2
   Rotate the overrunning clutch in both directions. It should lock in one direction and rotate smoothly in the other. If it locks in neither direction or locks in both directions, replace it.

   

3. 3
   If the starter pinion gear is worn or damaged, replace the overrunning clutch assembly (the pinion gear is not sold separately). Check the condition of the flywheel ring gear or torque converter if the starter pinion teeth are damaged.