Starter ASSY (FA20)
Components Inspection Removal / installation
STARTING
STARTER ASSY (FA20)
EXPLODED VIEW
REMOVAL
1. Disconnection of the battery ground terminal (Refer to 
)
)2. Removal of under cover COMPL T/M (Refer to )
)3. Removal of exhaust pipe ASSY FR (Refer to )
)
4. Removal of starter ASSY
(1) Disconnect the connector and terminal from the starter ASSY.
(2) Remove the wiring harness clamp.
(3) Remove the upper mounting bolt.
(4) Remove the lower mounting bolt.
1. Remove the ground cable fixing bolt A.
2. Remove the lower mounting bolt B.
3. Remove the starter ASSY.
2. Remove the lower mounting bolt B.
3. Remove the starter ASSY.
DISASSEMBLY
1. REMOVE MAGNET STARTER SWITCH ASSEMBLY(for Manual Transmission)
(1) Remove the nut and disconnect the lead wire from terminal M.
(2) Remove the 2 screws and the magnet starter switch assembly from the starter drive housing assembly.
2. REMOVE MAGNET STARTER SWITCH ASSEMBLY(for Automatic Transmission)
(1) Remove the nut and disconnect the lead wire from terminal M.
(2) Remove the 2 nuts and the magnet starter switch assembly from the starter drive housing assembly.
3. REMOVE STARTER YOKE ASSEMBLY (for Automatic Transmission)
(1) Using a "TORX" socket wrench T25, remove the 2 through bolts.
(2) Remove the starter yoke assembly and starter cover from the starter drive housing assembly.
4. REMOVE STARTER COVER (for Manual Transmission)
(1) Remove the 2 through bolts and 2 screws, and remove the starter cover.
5. REMOVE STARTER COVER (for Automatic Transmission)
6. REMOVE STARTER BRUSH HOLDER ASSEMBLY(for Manual Transmission)
(1) Remove the starter brush holder assembly.
NOTE:
Hold the brush with your fingers so that the brush spring does not come flying out.
7. REMOVE STARTER BRUSH HOLDER ASSEMBLY(for Automatic Transmission)
(1) Using a screwdriver, disengage the spring from the bush.
(2) Disconnect the 4 brush from the starter brush holder assembly.
(3) Remove the starter brush holder assembly.
8. REMOVE STARTER YOKE ASSEMBLY (for Manual Transmission)
(1) Remove the starter yoke assembly and starter armature assembly together from the starter drive housing assembly.
9. REMOVE STARTER ARMATURE ASSEMBLY (for Manual Transmission)
(1) Pull out the starter armature assembly from the starter yoke assembly.
10. REMOVE STARTER ARMATURE ASSEMBLY (for Automatic Transmission)
11. REMOVE STARTER ARMATURE PLATE (for Automatic Transmission)
12. REMOVE STARTER HOUSING RUBBER (for Manual Transmission)
13. REMOVE RUBBER SEAL (for Automatic Transmission)
14. REMOVE STARTER PLANETARY GEAR
(1) Remove the 3 starter planetary gears from the starter clutch sub-assembly.
15. REMOVE STARTER CLUTCH SUB-ASSEMBLY (for Manual Transmission)
(1) Remove the starter clutch sub-assembly together with the drive lever set pin from the starter drive housing assembly.
(2) Using a deep socket wrench, remove the stopper from snap ring.
(3) Using snap ring pliers, remove the snap ring and stopper.
(4) Pull out the over running clutch from the shaft.
INSPECTION
1. INSPECT STARTER ASSEMBLY
WARNING:
As a large electric current passes through the cable during this inspection, a thick cable must be used. If not, the cable may become hot and cause injury.
CAUTION:
The following tests must each be performed within 3 to 5 seconds to prevent the coil from burning out.
(1) Mount the starter in a vise between aluminum plates.
(2) Perform a pull-in test.
(a) Remove the nut, and then disconnect the lead wire from terminal M.
(b) Connect the battery to the starter as shown in the illustration. Check that the clutch pinion gear extends.
If the clutch pinion gear does not move, inspect the magnet starter switch assembly. If the magnet starter switch assembly is not as specified, replace it.
If the clutch pinion gear does not move, inspect the magnet starter switch assembly. If the magnet starter switch assembly is not as specified, replace it.
(3) Perform a holding test.
(a) Disconnect the negative (-) terminal lead from terminal M while the conditions specified in the pull-in test above are maintained. Check that the pinion gear remains out.
If the clutch pinion gear returns inward, inspect the magnet starter switch assembly. If the magnet starter switch assembly is not as specified, replace it.
If the clutch pinion gear returns inward, inspect the magnet starter switch assembly. If the magnet starter switch assembly is not as specified, replace it.
(4) Inspect the clutch pinion gear return.
(a) Disconnect the negative (-) terminal lead from the starter body. Check that the clutch pinion gear returns inward.
If the clutch pinion gear does not return inward, inspect the magnet starter switch assembly. If the magnet starter switch assembly is not as specified, replace it.
If the clutch pinion gear does not return inward, inspect the magnet starter switch assembly. If the magnet starter switch assembly is not as specified, replace it.
(5) Perform an operation test without load.
(a) Connect the lead wire to terminal C with the nut.
Standard value:
Standard value:
Tightening torque=10N·m
{
102kgf·cm}
{7.4ft·lbf}
(b) Connect the battery and an ammeter to the starter as shown in the illustration.
(c) Check that the starter rotates smoothly and steadily while the clutch pinion gear is extended. Then measure the current.
Standard Current
If the result is not as specified, inspect the starter assembly.| Tester Connection |
Condition |
Specified Condition |
|---|---|---|
| Battery positive terminal - Terminal B - Terminal M |
11.5 V |
Below 90 A |
NOTE:
Inspect the starter armature assembly, starter commutator end frame assembly and magnet starter switch assembly. If there is a malfunction, replace the part and perform again this test.
2. INSPECT STARTER ARMATURE ASSEMBLY (for Manual Transmission)
(1) Check the commutator for signs of seizure or stepped wear caused by roughness of the surface. If there is light wear, use sandpaper to repair.
(2) Check for runout on the commutator. If excessive, replace the armature.
Standard runout
: 0.05 mm (0.002 in.)
Maximum runout
: 0.10 mm (0.004 in.)
(3) Check the depth of the segment mold. If it is not within the standard, replace the armature.
Standard depth
: 0.05 mm (0.002 in.)
(4) Place the armature on the growler tester to check for short circuits. While slowly turning the armature, support the steel sheet for the armature core. If the circuit of the armature is shorted, the steel sheet will vibrate, causing it to move towards the core. When the steel sheet has moved or vibrated, replace the armature.
(5) Touch the probe of one side to the commutator segment, and the other probe to the shaft. If there is continuity, replace the armature.
3. INSPECT STARTER ARMATURE ASSEMBLY (for Automatic Transmission)
(1) Check the commutator for dirt and/or burns on the surface.If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe. If necessary,replace the starter armature assembly.
(2) Inspect the commutator for an open circuit.
(3) Inspect the commutator for short circuits.
(4) Check the commutator for signs of seizure or stepped wear caused by roughness of the surface.If there is light wear, use sandpaper to repair.
(5) Check for runout on the commutator. If excessive,replace the armature.
Standard runout
: 0.02 mm (0.0008 in.)
Maximum runout
: 0.05 mm (0.002 in.)
If the result is not as specified, replace the starter armature assembly.
(6) Using vernier caliper, measure the commutator diameter.
Standard diameter
: 29 mm (1.1417 in.)
Minimum diameter
: 28 mm (1.1024 in.)
If the diameter is less than the minimum, replace the starter armature assembly.
(7) Using vernier caliper, measure the under cut depth of the segment. If it is not within the standard, replace the starter armature assembly.
Standard depth
: 0.7 mm (0.0276 in.)
Minimum depth
: 0.2 mm (0.0079 in.)
4. INSPECT STARTER YOKE ASSEMBLY (for Manual Transmission)
(1) Make sure that the pole is set at the predetermined position.
5. INSPECT STARTER BRUSH HOLDER ASSEMBLY(for Manual Transmission)
(1) Visually check the brush. If there is any abnormal wear or cracks, replace the brush.
(2) Measure the length of the brush. If it exceeds the service limits, replace the brush.
Standard length
: 12.3 mm (0.484 in.)
Minimum length
: 7.0 mm (0.276 in.)
(3) Check that the brush moves smoothly in the brush holder.
(4) Measure the brush spring force with a spring scale.Replace the brush holder if below the service limit.
Standard brush spring force
: 15.9 to 19.5 N (1.6 to 2.0 kgf, 3.6 to 4.4 lbf)
Minimum brush spring force
: 2.5 N (0.3 kgf, 0.6 lbf)
6. INSPECT STARTER BRUSH HOLDER ASSEMBLY (for Automatic Transmission)
(1) Using a vernier caliper, measure the brush length.
Standard length
: 14.4 mm (0.5669 in.)
Minimum length
: 9.0 mm (0.3543 in.)
If the length is less than the minimum, replace the starter brush holder assembly.
7. INSPECT STARTER CLUTCH SUB-ASSEMBLY (for Manual Transmission)
(1) Check the gear teeth on the planetary gear, internal gear and starter clutch for wear or damage.
If any of the gears is damaged, replace the starter center bearing clutch sub-assembly.
If any of the gears is damaged, replace the starter center bearing clutch sub-assembly.
8. INSPECT MAGNET STARTER SWITCH ASSEMBLY(for Manual Transmission)
(1) Check that there is continuity between terminals 50 and C, and between terminal 50 and ground. Also, check to be sure there is no continuity between terminal C and 30.
(2) Using a lead wire, connect the switch assembly terminal 50 to the positive terminal of the battery, and the starter body to the ground terminal of the battery. The pinion should be forced to be pushed out on the shaft.
NOTE:
With the pinion forced to be pushed out on the shaft, the starter motor can sometimes rotate because the current flows, through pull-in coil, to motor. This is not a problem.
(3) Disconnect the connector from terminal M. Then, using a lead wire, connect the positive terminal of the battery and terminal M, and ground terminal to starter body. In this test set up, the pinion should return to its original position even when it is pulled out with a screwdriver.
9. INSPECT MAGNET STARTER SWITCH ASSEMBLY(for Automatic Transmission)
(1) Check the plunger.
(a) Push in the plunger and check that it returns quickly to it is original position.
If necessary, replace the magnet starter switch assembly.
If necessary, replace the magnet starter switch assembly.
(2) Inspect the pull-in coil.
REASSEMBLY
1. INSTALL STARTER CLUTCH SUB-ASSEMBLY (for Manual Transmission)
(1) Apply grease to the shaft as shown in the illustration.
Text in Illustration
 |
Multemp #6129 or equivalent |
(2) Install the internal gear to the shaft.
(3) Apply grease to the shaft as shown in the illustration.
Text in Illustration
|
|
Multemp #6129 or equivalent |
(4) Install the over running clutch to the shaft.
(5) Install the stopper to the shaft.
Using snap ring pliers, install the snap ring.
Using snap ring pliers, install the snap ring.
(6) Using a press, press the snap ring into the stopper.
(7) Install the starter clutch sub-assembly together with the drive lever set pin to the starter drive housing assembly.
2. INSTALL STARTER PLANETARY GEAR (for Manual Transmission).
3. INSTALL STARTER PLANETARY GEAR (for Automatic Transmission)
4. INSTALL STARTER HOUSING RUBBER (for Manual Transmission)
5. INSTALL RUBBER SEAL (for Automatic Transmission)
6. INSTALL STARTER ARMATURE ASSEMBLY (for Automatic Transmission)
7. INSTALL STARTER BRUSH HOLDER ASSEMBLY (for Automatic Transmission)
(1) Install the 4 brushes and 4 brush springs.
(2) Install the starter brush holder assembly to the starter armature assembly. Push the 4 brushes.
8. INSTALL STARTER COVER (for Automatic Transmission)
(1) Install the dust starter protector to the starter yoke assembly.
(2) Align the starter brush holder assembly read wire rubber with the groove of the starter cover.
(3) Install the starter cover to the starter brush holder assembly with 2 screws.
Standard value:
Standard value:
Tightening torque=1.5N·m
{
15kgf·cm}
{1.1ft·lbf}
9. INSTALL STARTER ARMATURE PLATE (for Automatic Transmission)
10. INSTALL STARTER ARMATURE ASSEMBLY (for Manual Transmission)
(1) Install the starter armature assembly to the starter yoke assembly.
11. INSTALL STARTER YOKE ASSEMBLY (for Manual Transmission)
12. INSTALL STARTER YOKE ASSEMBLY (for Automatic Transmission)
(1) Align the claw of the starter yoke assembly with the groove inside the starter drive housing assembly. Install the starter yoke assembly together with the starter armature assembly to the starter drive housing assembly.
(2) Using a "TORX" socket wrench T25, install the 2 through bolts.
Standard value:
Standard value:
Tightening torque=6.0N·m
{
61kgf·cm}
{4.4ft·lbf}
13. INSTALL STARTER BRUSH HOLDER ASSEMBLY (for Manual Transmission)
(1) Install a socket to the starter brush holder assembly.
(2) Install the starter brush holder assembly to the starter armature assembly.
14. INSTALL STARTER COVER (for Manual Transmission)
(1) Install the starter cover with 2 screws and 2 bolts.
Torque
: Bolt 6.0 N·m {61 kgf·cm} {4.4ft·lbf}
: Screw 1.4 N·m {14 kgf·cm} {1.0ft·lbf}
15. INSTALL MAGNET STARTER SWITCH ASSEMBLY (for Manual Transmission)
(1) Install the magnet starter switch assembly with the 2 screws.
Standard value:
Standard value:
Tightening torque=7.5N·m
{
77kgf·cm}
{5.5ft·lbf}
(2) Connect the lead wire to terminal C with the nut.
Standard value:
Standard value:
Tightening torque=10N·m
{
102kgf·cm}
{7.4ft·lbf}
16. INSTALL MAGNET STARTER SWITCH ASSEMBLY (for Automatic Transmission)
(1) Apply grease to the plunger and hook as shown in the illustration.
(2) Hook the plunger and hook of the magnet starter switch assembly to the lever of the starter drive housing assembly.
(3) Install the magnet starter switch assembly with the 2 screws.
Standard value:
Standard value:
Tightening torque=7.5N·m
{
77kgf·cm}
{5.5ft·lbf}
(4) Connect the lead wire to terminal C with the nut.
Standard value:
Standard value:
Tightening torque=10N·m
{
102kgf·cm}
{7.4ft·lbf}
INSTALLATION
1. Installation of starter ASSY
(1) Install the starter ASSY to the transmission and temporarily tighten the upper mounting bolt.
(2) Tightening the lower mounting bolt
1. Tighten the lower mounting bolt A.
Standard value
: 50 N·m {510 kgf·cm} {36.9 ft·lbf}
2. Tighten the ground cable fixing bolt B.Standard value
: 14 N·m {143 kgf·cm} {10.3 ft·lbf}
(3) Tighten the upper mounting bolt of starter ASSY using the SST.
Standard value:
SST
18283AA000
Standard value:
Specified tightening torque
Tightening torque=50N·m { 510kgf·cm} {36.9ft·lbf}
When using the SST, calculate the torque using the following formula.
Tightening torque=50N·m { 510kgf·cm} {36.9ft·lbf}
When using the SST, calculate the torque using the following formula.
Formula: T2 = L2/(L1 + L2) × T1
| T1 |
50 N·m |
| T2 |
Tightening torque |
| L1 |
Length of SST [0.085 m] |
| L2 |
Torque wrench length [m] |
NOTE:
·This torque value is valid when the SST and torque wrench are aligned on a line.
·Attach the SST and torque wrench so that they are aligned on a line.
·Attach the SST and torque wrench so that they are aligned on a line.
(4) Install the wiring harness clamp.
(5) Connect the connector and terminal to the starter ASSY.
2. Installation of exhaust pipe ASSY FR (Refer to )
)3. Installation of under cover COMPL T/M (Refer to )
)4. Connection of the battery ground terminal
Standard value:
Standard value:
Tightening torque=6.0N·m
{
61kgf·cm}
{4.4ft·lbf}