Vehicle check
1. Make sure the battery is fully charged.
2. The starter is normal if it rotates smoothly and without extraneous noise. If the starter does not work, remove it from the engine and check the technical condition. Check related wiring, ignition switch and transmission mode switch (AKP) or intermediate starter switch (ITUC).
Test without load
1. Make sure the battery is fully charged.
2. Connect the starter, battery and tester as shown.
3. Turn on the starter and make sure it turns smoothly. If the starter does not rotate smoothly, check the technical condition of the starter.
4. Measure the voltage and current while the starter is running. If the measurements are not correct, replace the starter with a new one.
Note:
Starter voltage without load: 11 V.
Starter current without load:
- cars with i-stop system: no more than 90A
- cars without i-stop system: no more than 95A
Retractor Check
Note: Depending on the state of charge of the battery, the starter gear may rotate in the extended position. This is due to the fact that the current flowing through the pull-in winding rotates the starter, which is not a malfunction.
Verify that the starter gear extends when connecting the positive pole of the battery to the starter terminal S and connecting the starter housing to ground. If the starter gear does not advance, repair or replace the starter.
Return Check
1. Disconnect the wire from the M terminal of the starter.
2. Connect the positive pole of the battery to the output M of the starter and connect the starter housing to ground.
3. Pull out the starter gear with a screwdriver. Verify that the gear returns to its original position when released. If the gear does not return to its original position, repair or replace the starter.
Gear clearance check (vehicles without i-stop system)
1. Connecting the positive pole of the battery to terminal S and connecting the starter housing to ground, extend the starter gear.
Attention. Applying voltage for more than 10 seconds may damage the starter. Do not apply voltage for more than 10 seconds.
2. Measure the clearance in the extended gear. If the measured value is not correct (0.5-2.0mm), adjust it with a suitable washer (between drive front cover and magnetic switch).
Checking the starter armature
1. Using a tester, verify that there is no continuity between the commutator and the armature core on each segment. If the circuit is closed, replace the armature with a new one.
2. Using a tester, verify that there is no continuity between the commutator and the shaft. If the circuit is closed, replace the armature with a new one.
3. Place the starter armature on the V-blocks and use a dial gauge to measure runout. If the measured value is not correct (no more than 0.1 mm), replace the anchor with a new one.
4. Measure the commutator diameter. If the value obtained does not correspond to the limit value (28.8mm), replace the anchor with a new one.
5. Measure the depth of the grooves between the commutator segments. If the measured value is less than the limit (0.2mm), cut grooves to standard depth (0.5mm).
Checking the starter magnetic switch
1. Using a tester, check the continuity between terminals S and M. If the circuit is open, replace the magnetic switch with a new one.
2. Using a tester, check the continuity between terminal S and the magnetic switch housing. If the circuit is open, replace the magnetic switch with a new one.
3. Using a tester, verify that there is no continuity between terminals M and B. If the circuit is closed, replace the magnetic switch.
Checking brushes and brush holder
1. Using a tester, make sure that there is no conductivity between each insulated brush and the brush holder plate. If the circuit is short, replace the brush holder with a new one.
2. Measure the length of the brushes. If at least one of the brushes is worn to the limit or so, replace all the brushes with new ones.
Note:
Starter brushes length:
- Standard: 12.3 mm.
- Minimum: 5.5 mm.
3. Using a dynamometer, measure the clamping force of the brush springs. If the measured value is less than the minimum (2.75 N), replace the brushes with the brush holder assembly with new ones.