Starting system (FA20)
Parts location System information Troubleshooting Inspection
STARTING
STARTING SYSTEM (FA20)
PARTS LOCATION
ON-VEHICLE INSPECTION
NOTE:
·The following check is performed with the starter mounted on the vehicle to measure the contact condition of starter magnet switch contact (hereinafter referred to as contact) electrically during engine cranking for check.
·If the contact is faulty, its contact resistance is too high and the time required for the contact to switch ON completely is long.
·If the contact is faulty, its contact resistance is too high and the time required for the contact to switch ON completely is long.
1. Starter ASSY check
(1) Contact resistance measurement method
NOTE:
·With the contact resistance measurement method, the resistance when the starter is energized is measured and the resistance increases when the contact is worn and its contact condition degrades.
·Since the contact resistance cannot be measured directly, it is calculated from the starter driving current and the voltage between the terminals.
·Since the contact resistance cannot be measured directly, it is calculated from the starter driving current and the voltage between the terminals.
(a) Check the DTC. (Refer to 
)
)CAUTION:
When a diagnostic code is detected, perform troubleshooting by code.
(b) Move the lock lever in the direction of arrow to unlock the three connectors.
Disconnect the three connectors with lock and normal connector from the injector driver.
Disconnect the three connectors with lock and normal connector from the injector driver.
Captions in illustration
| *1 |
Lock lever |
 |
Connector with lock |
 |
Normal connector |
| *a |
Unlock |
(c) Remove the three bolts and remove the injector driver.
(d) Remove the 2 bolts, and remove the intake manifold protector (bank 1 side).
(e) Disconnect the two connectors of fuel injector.
(f) Install the intake manifold protector (bank 1 side) with the two bolts.
Standard value:
Standard value:
Tightening torque=19N·m
{
194kgf·cm}
{14.0ft·lbf}
(g) Install the injector driver with the three bolts.
Standard value:
Standard value:
Tightening torque=6.4N·m
{
65kgf·cm}
{4.7ft·lbf}
NOTE:
Leave the two upper connectors of injector driver disconnected.
(h) Remove the 2 bolts, and remove the intake manifold protector (bank 2 side).
(i) Disconnect the two connectors of fuel injector.
(j) Measure the starter driving current while cranking at the position A in the figure five times. Calculate the average and record it.
Captions in illustration
| *1 |
Terminal S |
| *2 |
AC/DC probe 400A |
NOTE:
·Since the current generated by the generator may be measured depending on the measurement position, make sure that the current displayed on the electrical tester is within the range shown in the table and the starter driving current is measured properly.
·Perform the cranking for about 2 seconds and then read the value when the current indicated on the circuit tester stabilizes.
·Since the vehicle with the smart entry & start system is equipped with the cranking hold control, cranking is continued for a certain period of time when the engine does not start. To stop cranking, press the push button start switch again.
Starter driving current
·The starter driving current in the table indicates the reference value when the engine is hot.| Starter driving current |
Starter output |
|---|---|
| 100 to 180 A |
1.0 kW (transmission MT) 1.6 kW (transmission AT) |
·Perform the cranking for about 2 seconds and then read the value when the current indicated on the circuit tester stabilizes.·Since the vehicle with the smart entry & start system is equipped with the cranking hold control, cranking is continued for a certain period of time when the engine does not start. To stop cranking, press the push button start switch again.
Captions in illustration
| *1 |
Current change image |
| *2 |
Current |
| *3 |
Time |
| *4 |
STA ON |
|
|
Read the current value when the current change stabilizes. |
(k) Disconnect the battery ground terminal. (Refer to )
)
(l) Set the digital tester between the starter terminal M and engine wiring No. 2.
Captions in illustration
| *1 |
Terminal M |
| *2 |
Terminal S |
CAUTION:
Be careful not to short the terminal +B.
NOTE:
Attach alligator clips to the leads of electrical tester and secure them on the terminal M and the battery positive terminal side.
(m) Reconnect the battery ground terminal.
Standard value:
Standard value:
Tightening torque=6.0N·m
{
61kgf·cm}
{4.4ft·lbf}
(n) Measure the voltage between the starter terminal M and engine wiring No. 2 while cranking 20 times.
Captions in illustration
| *A |
Transmission M/T |
*B |
Transmission A/T |
| *1 |
Battery |
*2 |
AM2 No. 1 fuse |
| *3 |
AM1 fuse |
*4 |
Ignition OR starter switch |
| *5 |
INHIBITOR relay |
*6 |
Clutch start switch |
| *7 |
Neutral start switch |
*8 |
ST relay |
| *9 |
Engine control computer |
*10 |
ST fuse |
| *11 |
Terminal S |
*12 |
Terminal M |
| *13 |
Starter ASSY |
- |
- |
| *a |
Wiring harness connection diagram |
- |
- |
CAUTION:
·Be careful not to short the terminal +B.
·If the starter cannot be stopped while the measurement, remove the battery negative terminal to stop the starter, and then check the push button start switch or ignition (starter) switch ASSY, starter relay, starter ASSY and wiring harness. Replace the faulty parts.
·If the starter cannot be stopped while the measurement, remove the battery negative terminal to stop the starter, and then check the push button start switch or ignition (starter) switch ASSY, starter relay, starter ASSY and wiring harness. Replace the faulty parts.
NOTE:
·Since the contact conditions of moving contacts and fixed contacts vary during the operation, it is necessary to measure about 20 times.
·Perform the cranking for about 2 seconds and then read the value when the voltage indicated on the circuit tester stabilizes.
·Since the vehicle with the smart entry & start system is equipped with the cranking hold control, cranking is continued for a certain period of time when the engine does not start. To stop cranking, press the push button start switch again.
·Perform the cranking for about 2 seconds and then read the value when the voltage indicated on the circuit tester stabilizes.·Since the vehicle with the smart entry & start system is equipped with the cranking hold control, cranking is continued for a certain period of time when the engine does not start. To stop cranking, press the push button start switch again.
Captions in illustration
| *1 |
Current change image |
| *2 |
Voltage |
| *3 |
Time |
| *4 |
STA ON |
|
|
Read the current value when the current change stabilizes. |
(o) Calculate the voltage between the starter terminals from the measurement values above.
How to calculate the standard value
| Standard value (mV) = 2.5 mΩ (Starter criteria resistance) × Average value of starter driving current |
Calculation example
| Average value of starter driving current: 120 A Starter criteria resistance: 2.5 mΩ 120 × 2.5 = 300, and the standard value is 300 mV or less. |
Standard value
: Measurement voltage (mV) is equal to or less than standard value (mV).
NOTE:
Replace the starter contact if the measurement value exceeds the standard value even once among the 20 measurements.
Captions in illustration
| *1 |
Starter criteria resistance (1.5 mΩ) |
| *2 |
Starter driving current |
| *3 |
Measurement result |
| *4 |
Measured voltage |
(p) Disconnect the battery ground terminal. (Refer to )
)
(q) Remove the three bolts and remove the injector driver.
(r) Remove the 2 bolts, and remove the intake manifold protector (bank 1 side).
(s) Connect the two connectors of fuel injector.
(t) Using 2 bolts, install the intake manifold protector (bank 1 side).
Standard value:
Standard value:
Tightening torque=19N·m
{
194kgf·cm}
{14.0ft·lbf}
(u) Install the injector driver with the three bolts.
Standard value:
Standard value:
Tightening torque=6.4N·m
{
65kgf·cm}
{4.7ft·lbf}
(v) Connect the three connectors with lock to the injector driver.
Move the lock lever as shown in the figure to lock the three connectors with lock.
Move the lock lever as shown in the figure to lock the three connectors with lock.
Captions in illustration
| *1 |
Lock lever |
|
|
Connector with lock |
|
|
Normal connector |
CAUTION:
For connector with lock, connect the connector securely to lock it.
(w) Connect the two connectors of fuel injector.
(x) Using 2 bolts, install the intake manifold protector (bank 2 side).
Standard value:
Standard value:
Tightening torque=19N·m
{
194kgf·cm}
{14.0ft·lbf}
(y) Reconnect the battery ground terminal.
Standard value:
Standard value:
Tightening torque=6.0N·m
{
61kgf·cm}
{4.4ft·lbf}
(z) Make sure that there is no influence on the engine startability and after the engine is started.
HOW TO TROUBLESHOOT
NOTE:
The following is the flowchart to check the troubles of starter main body. For the vehicle with the smart entry & start system, check the smart entry & start system in advance to make sure that there is no fault is found in the smart entry & start system, and then perform the check according to the flowchart.
1.
Bring in the car
Next▼
2.
Interview and phenomenon check
(1) Does the engine start with one cranking?
Result
| Result |
Go to |
|
|---|---|---|
| Engine does not start |
Check (2) |
|
| Engine starts this time but did not start in the past |
Check (2) |
|
| Engine starts |
B |
|
(2) Does the engine crank normally?
Result
| Result |
Go to |
|
|---|---|---|
| Engine does not crank normally |
A |
|
| Engine cranks normally this time but did not crank normally in the past |
C |
|
| Engine cranks normally |
B |
|
B
>Starter normal
C
>Go to Step 4.
A▼
3.
Battery check
(1) Battery terminal check
(a) Check the battery terminals for looseness and damage.
(2) Battery voltage check
(a) To remove the voltage due to surface charging (ECU. capacitor etc.), turn the headlight switch to ON with IG OFF for about 20 or 30 seconds.
(b) Measure the battery voltage between the terminals.
Voltage
: 12.5 V or more (Electrolyte temperature: 20°C)
(3) Battery electrolyte level check
(a) Check the electrolyte level of each cell and refill distilled water or replace the battery if the level is below the LOW level.
(4) Battery electrolyte specific gravity check
(a) Check the electrolyte specific gravity in each cell.
Standard value
: 1.25 to 1.29 (Electrolyte temperature: 20°C)
NG
>Go to Step 5.
OK▼
4.
Starter check
(1) Perform the On-vehicle inspection (Refer to ).
).NG
>Go to Step 6.
OK▼
Complete
5.
Confirmation of past failure history
(1) Is there a symptom in which the engine could not be started or did not crank.
Result
| Result |
Go to |
|
|---|---|---|
| There was no such symptom |
A |
|
| There was the symptom |
B |
|
B
>Charge or replace the battery and then go to step 4
A▼
Charge or replace the battery to complete the check
6.
Starter repair or replacement
Next▼
Complete
CIRCUIT FIGURE
