1. |
Disconnect the battery negative
cable.
Tightening
torque:
(-) terminal : 4.0 ~ 6.0N.m (0.4 ~
0.6kgf.m, 3.0 ~ 4.4lb-ft)
| |
2. |
Disconnect the starter cable (A) from the B
terminal (B) on the solenoid (C), then disconnect the connector (D)
from the S terminal (E).

|
3. |
Remove the 2 bolts holding the starter, then
remove the starter.
Tightening
torque:
42.2 ~ 53.9N.m (4.3 ~ 5.5kgf.m, 31.1 ~
39.8lb-ft)
| |
4. |
Installation is the reverse of
removal. |
5. |
Connect the battery negative cable to the
battery. |
1. |
Disconnect the M-terminal (A) on the starter
solenoid assembly (B).

|
2. |
After loosening the 3 screws (A), detach the
starter solenoid assembly (B).

|
3. |
Loosen the through bolts (A).

|
4. |
Remove the brush holder assembly (A), yoke (b)
and armature (C).

|
5. |
Remove the packing (A) and shield
(B).

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

|
7. |
Disconnect the planet gear (A).

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

|
9. |
Press the stopper (A) using a socket
(B).

|
10. |
After removing the stop ring (A) using stop
ring pliers (B).

|
11. |
Disconnect the stop ring (A), overrunning
clutch (B), internal gear (C) and planet shaft (D).

Using a suitable pulling tool (A), pull
the overrunning clutch stopper (C) over the stop ring
(B). |

|
12. |
Reassembly is the reverse of
disassembly. |
Armature Inspection
And Test |
2. |
Disassemble the starter as shown at the
beginning of this procedure. |
3. |
Inspect the armature for wear or damage from
contact with the permanent magnet. If there is wear or damage,
replace the armature.

|
4. |
Check the commutator (A) surface. If the
surface is dirty or burnt, resurface with emery cloth or a lathe
within the following specifications, or recondition with #500 or
#600 sandpaper (B).

|
5. |
Measure the commutator (A)
runout.
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 run out is not within
the service limit, replace the
armature. |
Commutator
runout
Standard (New): 0.05mm (0.0019in.)
max
Service limit: 0.08mm
(0.0031in.)
|

|
6. |
Check the mica depth (A). If the mica is too
high (B), undercut the mica with a hacksaw blade to the proper
depth. Cut away all the mica (C) between the commutator segments.
The undercut should not be too shallow, too narrow, or v-shaped
(D).
Commutator
mica depth
Standard (New) : 0.8 mm (0.314
in.)
Limit : 0.2mm (0.0079
in.)
|

|
7. |
Check for continuity between the segments of
the commutator. If an open circuit exists between any segments,
replace the armature.

|
8. |
Check with an ohmmeter that no continuity
exists between the commutator (A) and armature coil core (B), and
between the commutator and armature shaft (C). If continuity exists,
replace the armature.

|
Inspect Starter Brush
Brushes that are worm
out, or oil-soaked, should be replaced.

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

|
2. |
Pry back each brush spring (A) with a
screwdriver, then position the brush (B) about halfway out of its
holder, and release the spring to hold it there.

|
3. |
Install the armature in the housing, and
install the brush holder. Next, pry back each brush spring again,
and push the brush down until it seats against the commutator, then
release the spring against the end of the brush.
To seat new brushes, slip a strip of
#500 or #600 sandpaper, with the grit side up, between the
commutator and each brush, and smoothly rotate the armature.
The contact surface of the brushes will be sanded to the same
contour as the commutator. |

|
Inspect Overrunning Clutch
1. |
Slide the overrunning clutch along the
shaft.
Replace it if does not slide
smoothly. |
2. |
Rotate the overrunning clutch both
ways.
Does it lock in one direction and rotate
smoothly in reverse? If it does not lock in either direction or it
locks in both directions, replace it.

|
3. |
If the starter drive gear is worn or damaged,
replace the overrunning clutch assembly. (the gear is not available
separately).
Check the condition of the flywheel or torque
converter ring gear if the starter drive gear teeth are
damaged. |
Cleaning
1. |
Do not immerse parts in cleaning solvent.
Immersing the yoke assembly and/or armature will damage the
insulation. Wipe these parts with a cloth
only. |
2. |
Do not immerse the drive unit in cleaning
solvent. The overrun clutch is pre-lubricated at the factory and
solvent will wash lubrication from the
clutch. |
3. |
The drive unit may be cleaned with a brush
moistened with cleaning solvent and wiped dry with a
cloth. | |