1. |
Disconnect the battery negative
terminal. |
2. |
Remove the air duct and air cleaner
assembly. (Refer to EM group) |
3. |
Disconnect the starter cable (B) from the B
terminal on the solenoid then disconnect the connector (A) from the
S terminal.

|
4. |
Remove the 2 bolts holding the starter, then
remove the starter (A).
Tighting
torque :
42.2 ~ 53.9 Nm (4.3 ~ 5.5 kgf.m, 31.1
~ 39.8 lb-ft)
|

|
5. |
Installation is the reverse of
removal. |
1. |
Disconnect the M-terminal (A) on the magnet
switch assembly (B).

|
2. |
After loosening the 2 screws (A), detach the
magnet switch assembly (B).

|
3. |
Loosen the brush holder mounting screw (A)
and through bolts (B).

|
4. |
Remove the rear bracket (A) and brush holder
assembly (B).

|
5. |
Remove the yoke (A).

|
6. |
Remove the packing (A), lever plate (B),
lever (C) and the armature (D).

|
7. |
Press the stopper (A) using a socket
(B).

|
8. |
Remove the stop ring (A) using stop ring
pliers (B).

|
9. |
Remove the stop ring (B), stopper (A),
overrunning clutch (C) and armature (D).

|
10. |
Reassembly is the reverse of
disassembly.
Using a suitable pulling tool (A),
pull the overrunning clutch stopper (C) over the stop ring
(B). |

|
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. |
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. |
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 (0.0020in.)
max
Service limit : 0.08mm (0.0031in.)
max
|

|
7. |
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) : 0.5mm
(0.0197in.)
Limit : 0.2mm (0.0079
in.)
|

|
8. |
Check for continuity between the segments of
the commutator. If an open circuit exists between any segments,
replace the armature.

|
9. |
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.
Bruch
length
Standard : 12.3 mm (0.4843 in)
Service limit : 5.5 mm (0.2165
in)
|

Starter
Brush Holder Test
1. |
Make sure 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.

| |
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. |
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. | |