Starter Motor

Specifications

Specification

▷12 V, 1.2 kW: ISG only

Item		Specification
Rated Voltage		12 V, 1.2 kW
Number of Gear Teeth		13
Performance [No Load, 11.5 V]	Amperes	Max. 117 A
	Speed	Min. 3200 rpm

Components and Component Location

Component

1. Front housing 2. Snap ring 3. Stopper 4. Overrunning clutch assembly 5. Internal gear assembly 6. Planetary shaft assembly 7. Planetary gear assembly 8. Packing 9. Shield

10. Lever plate 11. Lever packing 12. Lever 13. Magnetic switch assembly 14. Armature assembly 15. Yoke assembly 16. Brush holder assembly 17. Through bolt

Description and Operation

Description

The starting system consists of the battery, starter motor, magnetic switch, ignition switch, transaxle range (A/T) switch or clutch pedal switch (M/T), ignition switch, connecting wires, and battery cable. When the ignition key is turned to the START position, current flows and energizes the solenoid coil of the starter. When power is supplied, the solenoid plunger and shift lever are actuated, and the pinion gear engages with the ring gear, closing the contacts and cranking the starter motor. To prevent damage caused by excessive rotation of the armature when the engine starts, the pinion gear overruns (freewheels). In combination with the ISG function, the starter must operate reliably. This means more work. Therefore, the starter is designed for a significantly higher number of starting cycles. Starter components have been adapted to meet higher requirements.

1. Solenoid 2. Brush Assembly 3. Armature 4. Overrunning Clutch

Circuit Diagrams

Wiring Diagram

Repair Procedures

Removal

1. 1
   Turn the ignition switch OFF and disconnect the negative (-) battery terminal.
2. 2
   Remove the air cleaner. (Refer to Engine Mechanical System - "Air Cleaner")
3. 3
   Remove the intake manifold. (Refer to Engine Mechanical System - "Intake Manifold")
4. 4
   Remove the starter solenoid "B" terminal nut (B), then disconnect the starter cable and ST connector (A).

   Tightening Torque: 9.8–11.8 N·m

   

5. 5
   Remove the starter mounting bolts and remove the starter (A).

   Tightening torque: 42.2–54 N·m

   

   

Installation

1. Install in the reverse order of removal.

Installation

1. Assemble in the reverse order of disassembly.

Inspection

Armature Inspection and Test

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 caused by contact with the permanent magnet. If there is wear or damage, replace the armature.

   

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

   

5. 5
   Check the commutator diameter. If the diameter is less than the service limit, replace the armature. Commutator diameter Standard (new): 33.0 mm (1.2992 in) Service limit: 32.4 mm (1.2756 in)

   

6. 6
   Measure the commutator runout (A).

   • If the commutator runout is within the limit, check the commutator for carbon dust or brass chips between the segments.
   • If the commutator runout exceeds the service limit, replace the armature.

   Commutator runout Standard (new): 0.02 mm (0.0008 in) max. Service limit: 0.05 mm (0.002 in)

   

7. 7
   Check the mica depth (A). If the mica is too high (B), undercut the mica to the correct depth using a hacksaw blade. Cut away all mica (C) between the commutator segments. The undercut must not be too narrow or V-shaped (D). Commutator mica 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.

   

   

Inspect the starter brushes. Worn or oil-soaked brushes must be replaced.Starter Brush Holder Test

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

   

2. 2
   Slide the overrunning clutch along the shaft. Replace it if it does not slide smoothly.
3. 3
   Rotate the overrunning clutch in both directions. Check that it locks in one direction and rotates smoothly in the opposite direction. If it does not lock in either direction, or locks in both directions, replace it.

   

4. 4
   If the starter pinion gear is worn or damaged, replace the overrunning clutch assembly. (The gear is not sold separately.) If the starter pinion teeth are damaged, check the condition of the flywheel or torque converter ring gear.

Inspect the overrunning clutch.

Cleaning

1. 1
   Do not immerse the parts in cleaning solvent. Immersing the yoke and/or armature assembly may damage the insulation. Wipe these parts only with a cloth.
2. 2
   Do not immerse the drive in cleaning solvent. The overrunning clutch is pre-lubricated at the factory, and solvent will wash the lubricant out of the clutch.
3. 3
   The drive may be cleaned with a brush moistened with cleaning solvent and wiped dry with a cloth.