Page 1177 of 2267
1Pinion stopper
2Pinion assembly
3Gear case
4Pinion shaft assembly
5Shift lever
6Spring
7Holder
8Reduction gear
9Washer
10Center bracket
11Magnetic switch assembly
12Armature
13Yoke
14Brush (+)
15Brush spring
16Brush (-)
17Brush holder
18Rear cover
MEL780DB
SEC. 233
M2M62071
3.9 - 7.8
(0.40 - 0.80, 34.7 - 69.4)4.9 - 6.9
(0.50 - 0.70, 43.4 - 60.8)
2.5 - 4.4
(0.25 - 0.45, 21.7 - 39.1)
N·m (kg-m, in-lb)
MEL232M
STARTING SYSTEM
Construction (Cont’d)
EL-45
Page 1178 of 2267
1Bearing retainer
2Pinion shaft
3Clutch assembly
4Return spring
5Pinion stopper
6Stopper clip
7Gear case
8Dust cover
9Torsion spring
10Shift lever
11Magnetic switch assembly
12Armature assembly
13Field coil
14Yoke
15Brush (+)
16Brush spring
17Brush ( )
18Brush holder
19Rear cover
20Through-bolt
MEL233FB
SEC. 233
S13-531
6.4 - 7.8 (0.65 - 0.80, 56.4 - 69.4)
7.4 - 9.8
(0.75 - 1.00,
65.1 - 86.8)
N·m (kg-m, in-lb)
High temperature grease point
STARTING SYSTEM
Construction (Cont’d)
EL-46
Page 1179 of 2267
Removal and Installation
Removal
1. Remove battery negative cable from battery.
2. Remove intake air duct.
3. Remove starter motor mounting bolts.
4. Remove battery cable from starter motor.
5. Disconnect harness connector from starter motor harness.
6. Remove intake manifold support bracket.
7. Remove starter motor from under the vehicle.
Installation
Installation is reverse order of removal.
Inspection
MAGNETIC SWITCH CHECK
Before starting to check, disconnect battery ground cable.
Disconnect“M”terminal of starter motor.
1. Continuity test (between“S”terminal and switch body).
No continuity ... Replace.
2. Continuity test (between“S”terminal and“M”terminal).
No continuity ... Replace.
NEL301
:N·m (kg-m, ft-lb)
36 - 48 (3.7 - 4.9, 26.6 - 35.4)
YEL947C
NEL302 “M”terminal
“M”terminal Type 1
Type 2
STARTING SYSTEM
EL-47
Page 1180 of 2267

PINION/CLUTCH CHECK
1. Inspect pinion teeth.
Replace pinion if teeth are worn or damaged. (Also check
condition of ring gear teeth.)
2. Inspect reduction gear teeth.
Replace reduction gear if teeth are worn or damaged. (Also
check condition of armature shaft gear teeth.)
3. Check to see if pinion locks in one direction and rotates
smoothly in the opposite direction.
If it locks or rotates in both directions, or unusual resistance
is evident. ... Replace.
BRUSH CHECK
Brush cap and lever
Check wear of brush.
Wear limit length:
Refer to SDS (EL-52).
Excessive wear ... Replace.
Brush Spring Pressure
Check brush spring pressure with brush spring detached from
brush.
Spring pressure (with new brush):
Refer to SDS (EL-52).
Not within the specified values ... Replace.
Brush Holder
1. Perform insulation test between brush holder (positive side)
and its base (negative side).
Continuity exists. ... Replace.
2. Check brush to see if it moves smoothly.
If brush holder is damaged or deformed, replace it; clear
sliding surface if dirty.
NEL303 Type 1
Type 2
SEL014Z Vernier caliper
Brush
SEL015Z Brush spring
Brush
NEL304
Type 1
STARTING SYSTEM
Inspection (Cont’d)
EL-48
Page 1181 of 2267
YOKE CHECK
Magnet is secured to yoke by bonding agent. Check magnet to
see that it is secured to yoke and for any cracks. Replace mal-
functioning parts as an assembly.
Holder may move slightly as it is only inserted and not bonded.
CAUTION:
Do not clamp yoke in a vice or strike it with a hammer.
ARMATURE CHECK
1. Continuity test (between two segments side by side).
No continuity ... Replace.
2. Insulation test (between each commutator bar and shaft).
Continuity exists. ... Replace.
3. Check commutator surface.
Rough ... Sand lightly with No. 500 - 600 emery paper.
4. Check diameter of commutator.
Commutator minimum diameter:
Refer to SDS (EL-52).
Less than specified value ... Replace.
SEL018Z
Type 1
Type 2Magnet
Holder
Magnet
SEL019Z
SEL020Z Emery paper
SEL021Z Vernier caliper
Commutator
STARTING SYSTEM
Inspection (Cont’d)
EL-49
Page 1182 of 2267
M70R
5. Check depth of insulating mica from commutator surface.
Less than 0.3 mm (0.012 in) ... Replace.
S13-305, S13-531, S114-800B, S114-806A, S114-871,
M2M62071, 0 001 116 006
6. Check depth of insulating mold from commutator surface.
Less than 0.2 mm (0.008 in) ... Undercut to 0.5 to 0.8 mm
(0.020 to 0.031 in)
SEL207P 0,3 mm (0,012 in)
SEL022Z Round0.5 - 0.8 mm
(0.020 - 0.031 in)
Correct
File
Commutator
Segment
Mold
Incorrect
STARTING SYSTEM
Inspection (Cont’d)
EL-50
Page 1183 of 2267
Assembly
Apply high-temperature grease to lubricate the bearing, gears
and frictional surface when assembling the starter.
Carefully observe the following instructions.
PINION PROTRUSION LENGTH ADJUSTMENT
Clearance“l”
With pinion driven out by magnetic switch, push pinion back to
remove slack and measure clearance“l”between the front edge
of the pinion and the pinion stopper.
Clearance“l”:
Refer to SDS (EL-52).
Movement“”
Compare movement“”in height of pinion when it is pushed out
with magnetic switch energized and when it is pulled out by hand
until it touches stopper.
Movement“”
Refer to SDS (EL-52).
Not in the specified value ... Adjust by selecting the correct
adjusting plate.
SEL026Z Pinion stopper
Clearance“l”
SEL497D
NEL305 Adjusting plate
STARTING SYSTEM
EL-51
Page 1184 of 2267

Service Data and Specifications (SDS)
STARTER
TypeM70R M2T62071 0 001 116 006
MAGNETI MARELLI MITSUBISHI BOSCH
Reduction gear type Reduction gear type Non-Reduction
Applied model SR20 CD20TQG18
QG16
System voltage V 12
No load
Terminal voltage V 11.5 11.0 11.5
Current A 115 Less than 105 Less than 48
Revolution rev/min More than 4500 More than 4,030 More than 5,800
Min. commutator dia. mm (in) 28.8 (1.134) 31.4 (1.236) 33.5 (1.319)
Min. brush of length mm (in) 5.0 (0.197) 11.5 (0.453) 3.5 (0.138)
Brush spring tension N (kg, lb)14.3 - 25.2
(1.46 - 2.57,
3.22 - 5.69)13.7 - 25.5
(1.4 - 2.6,
3.1-5.7)5.2 (0.53, 1.17)
at 7.5 mm (0.295 in) brush
length
Movement“”in height of pinion
assembly mm (in)———
Clearance“I”between pinion front
edge & pinion stopper
mm (in)0-3.0(0-0.118)—0.0 - 3.9 (0 - 0.154)
Ty p eS114-806A S114-871 S13-305 S13-531 S114-800B
HITACHI
Reduction gear type
Applied model SR20SR20
with CVT modelsCD20TCD20T
cold areaQG18⋅QG16
cold area
System voltage V 12
No load
Terminal voltage V 11.0
Current A Less than 90 Less than 140 Less than 90
Revolution rev/min More than 2,700 More than 2,300 More than 3900 More than 2750
Min. commutator dia. mm (in) 28.0 (1.102) 35.5 (1.398) 28.0 (1.102)
Min. brush length mm (in) 10.5 (0.413) 11.0 (0.433) 10.5 (0.413)
Brush spring tension N (kg, lb) 16.2 (1.65, 3.64)12.7 - 17.7 (1.29 -
1.80, 2.84, 3.97)28.4 - 34.3 (2.90 - 3.50, 6.39 - 7.72)12.7 - 17.7
(1.29 - 1.80,
2.84 - 3.97)
Clearance between bearing &
armature shaft mm (in)Less than 0.2 (0.008)
Clearance“I”between pinion front
edge & pinion stopper
mm (in)0.3-2.5
(0.012 - 0.098)0.3-2.0
(0.012 - 0.079)0.3-0.8
(0.012 - 0.031)0.3 - 2.5
(0.012 - 0.098)
STARTING SYSTEM
EL-52