Starter (For Hatchback For Cold Area Specification Vehicles) Inspection

Perform a pull-in test.

1. Disconnect the field coil lead wire from terminal C.
   





2. Connect the battery to the magnet starter switch as shown in the illustration and check that the pinion gear moves outward.
   

   Text in Illustration

   *1	Terminal 50
   *2	Terminal C
   *3	Body

   If the clutch pinion gear does not move, replace the magnet switch assembly.
   

Perform a holding test.

1. Check that the pinion gear does not return inward after the cable is disconnected from terminal C.
   

   Text in Illustration

   *1	Terminal 50
   *2	Terminal C
   *3	Body

   If the clutch pinion gear returns inward, replace the magnet starter switch assembly.
   

Inspect the clutch pinion gear return.

1. Disconnect the negative (-) lead from the switch body.
   Check that the pinion gear moves inward.
   If the clutch pinion gear does not return inward, replace the magnet starter switch assembly.
   

Perform an operation test without load.

1. Connect the lead wire to terminal C.
   

   Torque:

   10 N*m{102 kgf*cm, 7.4 ft.*lbf}

2. Clamp the starter in a vise.
   





3. Connect the battery and ammeter to the starter as shown in the illustration.
   

   Text in Illustration

   *1	Terminal 50
   *2	Terminal 30
   *3	Body

4. Check that the starter rotates smoothly and steadily with the clutch pinion gear extended.
   Check that the ammeter indicates the specified current.
   

   Standard Current:

   Tester Connection	Condition	Specified Condition
   Battery positive terminal - Terminal 30 - Terminal 50	11.5 V	Below 90 A

Check the plunger.

1. Push in the plunger, then check that it returns quickly to its original position.
   If necessary, replace the magnet starter switch assembly.
   

Check the pull-in coil for an open circuit.

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

   Text in Illustration

   *1	Terminal 50
   *2	Terminal C

   Standard Resistance:

   Tester Connection	Condition	Specified Condition
   Terminal 50 - Terminal C	Always	Below 1 Ω

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

Check the holding coil for an open circuit.

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

   Text in Illustration

   *1	Terminal 50
   *2	Switch Body

   Standard Resistance:

   Tester Connection	Condition	Specified Condition
   Terminal 50 - Body ground	Always	Below 2 Ω

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

Check the commutator.

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

   Standard Resistance:

   Tester Connection	Condition	Specified Condition
   Segment - Segment	Always	Below 1 Ω

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

Check the commutator.

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

   Standard Resistance:

   Tester Connection	Condition	Specified Condition
   Commutator - Armature	Always	10 kΩ or higher

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

Check the commutator surface for dirt and burns. If the surface is dirty or burnt, restore it with sandpaper (No. 400) or a lathe.

Check the commutator circuit for runout.

1. Place the commutator 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 greater than the maximum, replace the armature assembly.
   

Using a vernier caliper, measure the commutator diameter.

Standard diameter:

29 mm (1.14 in.)

Minimum diameter:

28 mm (1.10 in.)

Check that the undercut portion is clean and free of foreign matter. Smooth out the edges.

Standard undercut depth:

0.7 mm (0.0276 in.)

Minimum undercut depth:

0.2 mm (0.00787 in.)

Remove the claw of the spring, then remove the 4 brushes.

Using a vernier caliper, measure the brush length.

Standard length:

14.4 mm (0.567 in.)

Minimum length:

9.0 mm (0.354 in.)

Check the brush holder.

1. 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	Always	10 kΩ or higher
   A - D	Always	Below 1 Ω
   B - C	Always	Below 1 Ω
   B - D	Always	10 kΩ or higher
   C - D	Always	10 kΩ or higher

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

Check the gear teeth of the planetary gear and starter center bearing clutch for wear or damage.
If any planetary gear is damaged, replace the planetary gear assembly.
If any gear of the starter center bearing clutch is damaged, replace the starter center bearing clutch sub-assembly.

Check the movement of the clutch pinion gear.

1. Hold the starter clutch, rotate the clutch pinion gear clockwise, and check that it turns freely.
   Try to rotate the clutch pinion gear counterclockwise and check that it locks.
   If the clutch pinion gear cannot be turned clockwise smoothly, or does not lock in the counterclockwise direction, replace the starter center bearing clutch sub-assembly.