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Î
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(#'
) Specification
Electric Current: 80 A or less
4-9
Starter Performance Test
STARTER
S
B
S STARTER B STARTER
S
B
1. Remove the starter (see page 4-10).
2. Make the connections for this test using the thickest
(gauge) wire possible (preferably the same gauge
as used on the vehicle).
NOTE: To avoid damaging the starter, never leave
the battery connected for more than 10 seconds.
3. Connect the battery as shown, and check for continuity between the B terminal and the starter
body. If there is continuity, it is working properly.
4. Disconnect the battery from the starter body, and check for continuity between the B terminal and the
starter body. If there is no continuity, it is working
properly. 5. Firmly clamp the starter in a vise.
6. Connect the starter to the battery as shown, and
confirm that the motor runs.
7. If the electric current meets the specification when the battery voltage is at 11.5 V, the starter is
working properly.
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(#'
)
Removal
K20Z2 engine
K20Z3 engine
4-10 Starting System
Starter Removal and Installation
1. Do the battery terminal disconnection procedure
(see page 22-68).
2. Remove the splash shield. 3. Remove the intake manifold bracket.
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Î
Î
Î
Installation
4-11
A
B
A
BC B
CA 8x1.25mm
9 N·m (0.9 kgf·m, 7 lbf·ft)
10x1.25mm
44 N·m
(4.5 kgf·m, 33 lbf·ft) 10x1.25mm
64 N·m
(6.5 kgf·m, 47 lbf·ft)
A
4. Remove the harness clamp (A), then the two bolts(B) securing the starter, then remove the starter
from the engine.
5. Disconnect the positive starter cable (A) and the S terminal connector (B).
6. Remove the harness clamp (C), then remove the starter. 1. Install the harness clamp (A).
2. Connect the positive starter cable (B) and S
terminal connector (C). Make sure the starter cable
crimped side of the ring terminal faces away from
the starter when you connect it.
3. Install the starter, and tighten the two bolts, then install the harness clamp (A).
(cont’d)
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Page 60 of 2893
K20Z2 engine
K20Z3 engine
4-12 Starting System
Starter Removal and Installation (cont’d)
8x1.25mm
22 N·m
(2.2 kgf·m, 16 lbf·ft)
8x1.25mm
22 N·m
(2.2 kgf·m, 16 lbf·ft)
4. Install the intake manifold bracket. 5. Install the splash shield.
6. Do the battery terminal reconnection procedure (see page 22-68).
7. Start the engine to make sure the starter works properly.
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Î
(#'
!) Disassembly/Reassembly
4-13
Starter Overhaul
PLANETARY GEARS
RING GEAR HOLDER
SWITCH PLUNGER
GEAR COVER ASSEMBLY
SWITCH SHAFT DRIVE PLATE
BRUSH SPRING
BRUSH HOLDER
PUSH NUT
END COVER
ARMATURE HOUSING ARMATUREGEAR PLUNGER
CONTACT SPRING MOVING CONTACT
(cont’d)
Apply molybdenum
disulfide. Apply molybdenum
disulfide.
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Page 62 of 2893

ÌÌ
µµ
Armature Inspection and Test
Commutator Diameter
Standard (New): 28.0 28.1 mm (1.102 1.106 in.)
Service Limit: 27.5 mm (1.083 in.)
Commutator Runout
Standard (New): 0.02 mm (0.0008 in.) max.
Service Limit: 0.05 mm (0.002 in.)
4-14Starting System
Starter Overhaul (cont’d)
A
BA
1. Remove the starter (see page 4-10).
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 it with an emery cloth or a
lathe to the specifications in step 5, or recondition
with 500 or 600 sandpaper (B). 5. Check the commutator diameter. If the diameter is
below the service limit, replace the armature.
6. Measure the commutator (A) runout. If the commutator runout is within the servicelimit, check the commutator for carbon dust or
brass chips between the segments.
If the commutator runout is not within the service limit, replace the armature.
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µµ
Commutator Mica Depth
Standard (New): 0.40 0.50 mm (0.016 0.020 in.)
Service Limit: 0.15 mm (0.006 in.)
4-15
A
B
C
D C
B
A
A
B
C
7. Check the mica depth (A). If the mica is too high (B),
undercut the mica with a ha cksaw 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).
8. Use an ohmmeter to check for continuity between the segments of the commutator. If there is an
open circuit between any of the segments, replace
the armature. 9. Place the armature (A) on an armature tester (B).
Hold a hacksaw blade (C) on the armature core. If
the blade is attracted to the core or vibrates while
the core is turned, the armature is shorted. Replace
the armature.
10. Use an ohmmeter check for continuity between the commutator (A) and the armature coil core (B), and
the between the commutator and the armature
shaft (C). If there is continuity, replace the armature.
(cont’d)
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´
µ
Î
µµ
Starter Brush Inspection
Brush Length
Standard (New): 11.1 11.5 mm (0.44 0.45 in.)
Service Limit: 4.3 mm (0.17 in.)
Starter Brush Holder Test Planetary Gear Inspection
4-16Starting System
Starter Overhaul (cont’d)
B
AB
A
11. Measure the brush length. If it is shorter than theservice limit, replace the brush holder assembly.
12. Check for continuity between the ( ) brushes (A) and the ( ) brushes (B). If there is continuity,
replace the brush holder assembly. 13. Check the planetary gears (A) and the internal ring
gear (B). Replace them if they are worn or damaged.
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