STARTlNG SYSTEM - Specifications 8-133

STARTING SYSTEM
SPECIFICATIONS
GENERAL SPECIFICATIONS NC#E-
Items 2.6L Engine 3.OL Engine
Starter motor
Type Reduction drive Reduction drive
Model No. MlT70481 MIT72581
Part No. MD099667 MD136933
Rated output kWN 1.2/12 1.2/12
No. of pinion teeth 8 8

SERVICE SPEClflCATlONS NMFC-

Items Specifications
Standard values
Starter motor
Free running characteristics
Terminal voltage V 11
Current A Max. 90
Speed rpm Min. 3000
Under-cut depth mm (in.) 0.5 (.020)
Commutator diameter mm (in.) 29.4 (1.157)
Pinion gap mm (in.) 0.5-2.0 (.020-.079)
Commutator runout mm (in.) 0.05 (.0020)
-imit
Commutator diameter mm (in.) 28.8 (1.134)
Commutator runout mm (in.) 0.1 f.004)

TORQUE SPEClFlCATlONS NMFD-

Items Nm ft.lbs.

Starter motor mounting bolts 27-34 20-24

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 8-134 STARTING SYSTEM - Troublesbooting
TROUBLESHOOTING
STARTING CIRCUIT Ignition switch
C:IRCUIT DIAGRAM
<Vehicles with a Manual Transmission>

Main fusible
Batten! link

t3.0L Engine only>

B-01
.&a

Remark
I?) Lines and connectors indicated by the * symbol are
applicable to the 2.6liter models.
(2) The broken line (----I is applicable to the 3.0-liter
models only.
(3) For information concerning the ground points (example:
0). refer to P.812, 14.
Wiring color code
6: Black Br: Brown G: Green ;;:$$v L: Blue Lg: Light green
LI: Light blue 0: Orange P: Pink Y: Yellow W: White

OPERATION TROUBLESHOOTING NINTS

l When the ignition switch is turned to “START” 1. Starter motor does not turn over
with the inhibitor switch in “P” or “N” position 1) Starter motor operating sound is heard for
(automatic transmission vehicles), current an instant
flows through the inhibitor switch and starter l Check starter motor for condition of its
coil to ground. This closes the contacts of the magnetic switch. --
starter switch (magnetic switch). 2) Starter motor does not operates at all -
E .-

l Closing the magnetic switch contacts com- l Check starter motor coils. --

pletes the circuit from the battery to magnetic 2. Starter motor does not stop
switch to starter motor and ground, so that the i l Checkstarter motor for condition of its
starter motor starts rotating. magnetic switch. p--i
_
I l-CR Rawieirm
 STARTING SYSTEM - Circuit Diagram 8-135

<Vehicles with an Automatic Transmission>

Ignition switch

Battery

C-56

Inhibitor
switch

Remark
For infomation concerning the ground points (example: 110,
refer to P.8-14.
Wiring color code
B: Black Br: Brown G: Green
LI: Light blue 0: Orange P: Pink
L: Blue
Y: Yellow

Starter -

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 ----mu
_-__ : -t ~_ ..,.

8-136 STARTING SYSTEM - Starter Motor

STARTER MOTOR
REMOVAL AND INSTALLATION NoIFJ*N

<2.6L Engine> l Drainage of Automatic Transmission

/ 6 Removal of Oil Cooler Tube. (Refer

P Post-installation
l
l
Operation
Installation of Oil Cooler Tube.
Supplying of Automatic Transmission
Fluid. (Refer to GROUP 21 -
Transmission Oil Cooler)

\
27-34 Nm
20-25 ftlbs.

<3.OL Engine> r/

Removal steps
1. Connection for starter motor connector
2. Starter cover
l * 3. Starter motor
NOTE
(1) Reverse the removal procedures to reinstall.
(2) ** : Refer to “Service Points of Removal.”

SERVICE POINTS OF REMOVAL

3. REMOVAL OF STARTER MOTOR
Models with manual transmission
Jack up the vehicle; then remove (from below the body)
the starter motor mounting bolts, and separate the starter
motor from the transmission assembly.

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 STARTING SYSTEM - Starter Motor 8-137
INSPECTION
PINION GAP ADJUSTMENT
(1) Disconnect field coil wire from “M”-terminal of magnetic
switch.
(2) Connect a 12V battery between “S’‘-terminal and “M”-

yp/(zJ motor
terminal.
(3) Set switch to “ON”, and pinion
Caution
This test must be performed
will move out.

quickly (in less than 10

L-J BELo seconds) to prevent coil from burning.

(4) Check pinion to stopper clearance (pinion gap) with a

feeler gauge.
Standard value: 0.5-2.0 mm (.020-.079 in.)

Pinion

(5) If pinion gap is out of specification, adjust by adding or

removing gaskets between magnetic switch and front
bracket.

PULL-IN TEST OF MAGNETlC SWITCH

(1) Disconnect field coil wire from M-terminal of magnetic
switch.
(2) Connect a 12V battery between S-terminal and M-ter-
minal.
Caution
This test must be performed quickly (in less than 10
Field coil wire seconds) to prevent coil from burning.
(3) If pinion moves out, then pull-in coil is good. If it doesn’t
replace magnetic switch.

HOLD-IN TEST OF MAGNETIC SWITCH

(I) Disconnect field coil wire from M-terminal of magnetic
switch.
(2) Connect a 12V battery between S-terminal and body.
Caution
This test must be performed quickly (in less than 10
seconds) to prevent coil from burning.
(3) If pinion remains out, everything is in order. If pinion
Field coil wire moves in, hold-in circuit is open. Replace magnetic
switch.
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8-138 STARTING SYSTEM - Starter Motor

Carbon-pile rheostat FREE RUNNING TEST

(1) Place starter motor in a vise equipped with soft jaws and
connect a fully-charged 12-volt battery to starter motor as
follows:
(2) Connect a test ammeter (IOO-ampere scale) and carbon
pile rheostat in series with battery positive post and
starter motor terminal.
(3) Connect a voltmeter (1 Ervolt scale) across starter motor.
(4) Rotate carbon pile to full-resistance position.
(5) Connect battery cable from battery negative post to
starter motor body.
(6) Adjust rheostat until battery voltage shown on the volt-
meter reads 1 IV.
(7) Confirm that the maximum amperage is within the stan-
dard value and that the starter motor turns smoothly and
freely.
Standard value: Current Max. SOA
Speed Min. 3,000 rpm

RETURN TEST-OF MAGNETIC SWITCH

(II Disconnect field coil wire from M-terminal of magnetic
switch.
(2) Connect a 12V battery between M-terminal and body.
Caution
This test must be performed quickly (in less than IO
seconds) to prevent coil from burning.
(3) Pull pinion out and release. If pinion quickly returns to its
original position, everything is in order. If it doesn’t,
replace magnetic switch.

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 STARTING SYSTEM - Starter Motor 8-739
DISASSEMBLY AND REASSEMBLY

Disassembly steps
1. Screw
2. f&gnetic switch h[ ‘A\\
3. Screw
4. screw
5. Rear bracket
6. Brush holder
7. Brush
8. Rear bearing
l * 9. Armature
IO. Yoke assembly
*+ 11. Ball EL199
12. Packing A
13. Packing B
14. Plate
15. Planetary gear
16. Lever -
+I)** 17. Snap ring NOTE
+I)** 18. Stop ring (1) Reverse the disassembly procedures to reassemble.
19. Over running clutch (2) +* : Refer to “Service Points of Disassembly”.
20. Internal gear (3) l + : Refer to “Service Points of Reassembly”.
21. Planetary gear holder
22. Front bracket

SERVICE POINTS OF DISASSEMBLY

9. REMOVAL OF ARMATURE / 11. BALL
When removing the armature, do not lose the ball which
acts as a bearing for the armature and tip.

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8-140 STARTING SYSTEM - Starter Motor
17. REMOVAL OF SNAP RING / 18. STOP RING
Socket (I) Push the stop ring towards the snap ring using the
proper socket.
(2) After removal of the snap ring with the snap ring
Stop ring Pinion gear pliers, remove the stop ring and the over-running
clutch.
CIwmning

6ELOO97

Snap ring CLEANING STARTER MOTOR PARTS

1. Do not immerse parts in cleaning solvent. Immersing the
yoke and field coil assembly and/or armature will damage
insulation. Wipe these parts with a cloth only.
2. Do not immerse drive unit in cleaning solvent. Overrun-
ning clutch is pre-lubricated at the factory and solvent will
wash lubrication from clutch.
3. The drive unit may be cleaned with a brush moistened
with cleaning solvent and wiped dry with a cloth.

INSPECTION
CHECKING COMMUTATOR
(1) Plate the armature on a pair of V blocks and check
run-out with a dial gauge.
Standard value: 0.05 mm LOO20 in.)
Limit: 0.1 mm l.004 in.1

(2) Check the outer diameter.

Standard value: 29.4 mm (1.157 in.)
Limit: 28.8 mm (1.134 in.)

(3) Check the depth of the undercut between segments.

Undercut
Standard value: 0.5 min. (.020 in.)

lEl.OS!3~
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 STARTING SYSTEM - Starter Motor 8-141
BRUSH HOLDER
Check conductivity between the brush holder plate and brush
holder. It there is no conductivity this is normal.

OVERRUNNING CLUTCH
1. While holding clutch housing, rotate the pinion. Drive
pinion should rotate smoothly in one direction, but should
not rotate in opposite direction. If clutch does not func-
tion properly, replace overrunning clutch assembly.
2. Inspect pinion for wear or burrs. If pinion is worn or
burred, replace overrunning clutch assembly. If pinion is
damaged, also inspect ring gear for wear or burrs.

FRONT AND REAR BRACKET BUSHING

Inspect bushing for wear or burrs. If bushing is worn or

l&l
burred, replace front bracket assembly or rear bracket

n
assembly.

REPLACEMENT OF BRUSHES AND SPRINGS

1. Brushes that are worn beyond limit line, or are oil-soaked,
should be replaced.
2. When replacing field coil brushes, crush worn brush with
-Limit line
pliers, taking care not to damage pigtail.

3. Sand pigtail end with sandpaper to ensure good

New brush soldering.
I 4. Insert pigtail into hole provided in new brush and solder
it. Make sure that pigtail and excess solder do not come
out onto brush surface.
5. When replacing ground brush, slide the brush from brush
holder by prying retaining spring back.

Glower TESTING ARMATURE

TESTING ARMATURE FOR SHORT-CIRCUIT
1. Place armature in a growler.
2. Hold a thin steel blade parallel and just above while
rotating armature slowly in growler. A shorted armature
will cause blade to vibrate and be attracted to the core.
Replace shorted armature.

-
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 TESTING ARMATURE FOR GROUNDING ml%=-
-3:
Check the insulation in the space between the segments of s-!
the commutator and the armature and coil core. If there is no
conductivity this is normal.

CHECKING CIRCUIT BRAKE BETWEEN ARMATURE AND

COIL
Check conductivity between each segment. If there is con-
ductivity this is normal.

SERVICE POINTS OF REASSEMBLY

18. INSTALLATION OF STOP RING / 17. SNAP RING
Using a suitable pulling tool, pull overrunning clutch stop
ring over snap ring.

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 IGNITION SYSTEM - lanition &stem c2.6L Engine> 8-153
SERVICE POINTS OF INSTALLATION
5. INSTALLATION OF DISTRIBUTOR
Gear’s matinal (1) Turn the crankshaft so that the No. 1 cylinder is at top
dead center.
(2) Align the distributor housing and gear mating marks.

(3) Install the distributor to the engine while aligning the

fine cut (groove or projection) of the distributor’s
installation flange with the center of the distributor
installation stud.

/
Housin
mark

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8-154 IGNlTlON SYSTEM - ignition System <Z&L Engine>
1. INSTALLATION OF SPARK PLUG CABLE
Improper arrangement of spark plug cables will induce
voltage between the cables, causing miss firing and
developing a surge at acceleration in high-speed opera-
tion. Therefore, be careful to arrange the spark plug
cables properly by the following procedure.

1. Install the spark plug cable clamps as shown in the

illustration.
2. The numerals on the support and clamp indicate the
spark plug cable No.
3. Pay attention to the following items when the spark
plug cables are installed.
(I) Install the cables securely to avoid possible con-
tact with metal parts.
(2) Install the cables neatly, ensuring they are not too
tight, loose, twisted or kinked.

View P

5ELma

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 -

IGNITION SYSTEM - Ignition System <&OL Engine>

IGNllTlON SYSTEM <3.OL ENGINE>

REMOVAL AND INSTALLATION

20-30 Nm
15-21 ft.lbs.

12-15 Nm
.9-l 1 ft.lbs.

+Q $4 1. Spark plug cable

2. Spark plug
a* 3. High tension cable 7EL0061
a*+ 4. Distributor
5. Ignition coil assembly

NOTE
(1) +I) : Refer to “Service Points of Removal”.
(2) P)*4 : Refer to “Service Points of Installation”.

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8-l 56 IGNITION SYSTEM - Ignition System <3.OL Engine>

SERVICE POINTS OF REMOVAL

1. REMOVAL OF SPARK PLUG CABLE/3. HIGH TENSION
CABLE
Refer to P.8-151.

INSPECTION
SPARK PLUG
Refer to P.8-152.

SPARK PLUG CABLE

(1) Check cap and coating for cracks.
(2) Measure resistance.
Unit: kLI

I High tension cable

Approx. 3
I

) 9
I

1 8.5
I

10
I

9 ‘12 IO

00 High-
voltage
terminal
IGNITION COIL
(1) Measurement of the primary coil resistance
Measure the resistance of the positive (+I terminal and
negative (-) terminal of the ignition coil.
Standard value: 0.72-0.99 rc2
(2) Measurement of the secondary coil resistance
Measurement the resistance of the positive (+) terminal
and the high-voltage terminal.
Standard value: 10.3-13.9 ka
?ELoos7

POWER TRANSISTOR
(1) Connect the negative (-) terminal of the 1.W power
supply to terminal @ of the power transistor, then check
whether there is continuity between terminal @ and
terminal @ when terminal @ and the positive (+) termin-
al are connected and disconnected.

lTertninal @ and (+) terminal ( Terminal @ and terminal @ 1

Connected Continum/
6El0103
Unconnected No contirruity.

(2) Replace the power transistor if there is a malfunction.

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IGNITION SYSTEM - Ignition System <3.0L Engine> 8-157
SERVICE POINTS OF INSTALLATION
4. lNSTALLATlON OF DlSTRlBUTOR
Mating (1) Turn the crankshaft so that the No. 1 cylinder is at top
mark dead center.
(2) Align the distributor housing and gear mating marks.

7EL0058

(3) Install the distributor to the engine while aligning the

fine cut (groove or projection) of the disbributor’s
installation flange with the center of the distributor
installation stud.

1. INSTALLATION OF SPARK PLUG CABLE

Refer to P. 8-154.

7EL0060

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8-158 IGNITION SYSTEM - Distributor <2.6L Engine>

DKI-RIBUTOR <2.6L ENGINE>

9 11

4.3\I
21
20
15 I

Engines for
Disassembly steps Federal
& e
1. Breather
2. Distributor cap
3. Packing
;. i~&&tct carbon

6: Vacuum control
7. Ground wire
8. Lead wire
I)+ ;dyE;nt of air gap
+I) 10: 8 otor shaft
4* ++ 11. Signal rotor
I)4 12. Breaker plate
2: 14. Spring
13. Governorretainer
spring
lEL0003
15. Governor weight
16. Lock pin
+I) ++ 17. Driven gear
18. Washer
19. O-ring NOTE
20. Distributor shaft ;;I F;rse the disassembly pro!edures to reassemble.
21. Washer . Refer to “Servrce Pornts of Disassembly”.
22. Oil seal :. Refer to “Service Points of Reass-embly”.
23. Distributor housing : Non-reusable parts

SERVICE POINTS OF DISASSEMBLY

10. REMOVAL OF ROTOR SHAFT/ll. SIGNAL ROTOR
Place igniter base on soft base (wooden block) and lightly
tap rotor shaft to remove it from signal rotor.

levision
 IGNITION SYSTEM - Distributor <ML Engine> 8459
13. REMOVAL OF SPRING RETAINER/14. GOVERNOR
SPRING
Remove two spring retainers with pliers and then remove
two governor springs.

*Pin punch 17. REMOVAL OF DRIVEN GEAR

II Distributor
(1) Mark location of driven gear on distributor shaft.
(2) Place driven gear on soft base (wood btock) so that
spring pin can be removed.
(3) Using a pin punch, remove spring pin.

Contact carbon INSPECTION

Check according to the following provisions and repair or
replace anything faulty.
CAP ROTOR
(1) Ensure there are no cracks in the cap.
(2) Ensure that the electrodes of the cap and of the rotor are
undamaged.
(3) Wipe off any dirt from the cap or the rotor.

&Pin punch SERVICE POINTS OF REASSEMBLY

II Distributor
Before servicing be sure to clean and inspect all parts.

17. INSTALLATION OF DRIVEN GEAR

Install driven gear into distributor shaft at previously
marked location.

12. INSTALLATION OF BREAKER PLATE

Install igniter base to housing. Position the igniter base so
that the projection (A) fits into the groove (B).

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 IGNITION SYSTEM - Distributor ~2.6~ EngineHDiibutor -4.0~ Engine>

11. INSTALLATION OF SIGNAL ROTOR

install signal rotor to rotor shaft. Position the signal rotor
Socket
so that the dowel pin fits into the groove.

* ADJUSTMENT OF AIR GAP

Adjust air gap between signal rotor and pickup or igniter.
Standard value: 0.8 mm (.0315 in.)

DlSTRlBUTOR <3.OL ENGINE>

DISASSEMBLY AND REASSEMBLY

8 5 7

I I I

Disassembly steps
1. Distributor cap
2. O-ring
3. Contact carbon
4. Rotor
5. Lead wire
6. Spring pin
++r)+ 7. Driven gear
8. O-ring
9. Distributor housing assembly

NOTE
1;; Fy the disassembly procedures to reassemble.
: Refer to “Service Points of Disassembly”.
: Refer to “Service Points of Reassembly”. 7ELOO62
: Non-reusable parts

=zzr
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 IGNITION SYSTEM - Distributor <3.OL Enaine> 8-761
Punch SERVICE POINTS OF DISASSEMBLY
7. REMOVAL OF DRIVEN GEAR
(1) Make a position identification mark (for the drive gear)
on the distributor shaft.
(2) Place the drive gear on a soft base (wooden block) so
that the spring pin can come out.
(3) Punch out the spring pin by using a pin punch.

INSPECTION
Check the following points; repair or replace if a problem is
found.

CAP ROTOR
(1) There must be no cracking in the cap.
(2) There must be no damage to the cap’s electrode or the
rotor’s electrode.
(3) Clean away any dirt from the cap and rotor.
7ELOo64

SERVICE POINTS OF REASSEMBLY

Take out and clean the disassembled parts. Do not use
cleaning oil or similar product for cleaning.

7. INSTALLATION OF DRIVEN GEAR

(1) Align with the mark made at the time of disassembly,
and install the drive gear to the distributor shaft.

(2) When aligning the driven gear’s mating mark and the
housing’s mating mark, make the combination so that
“A” (rotor mounting threaded hole) at the shaft end is
at the position shown in the figure, and then align the
spring pin hole and drive in a new spring pin.
Caution
Drive in the spring pin so that the slits are at a
right angle dative to the shaft.

7EL0065

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8462 IGNITION SYSTEM - lanition Switch

IGNITION SWITCH
REMOVAL AND INSTALLATION

Removal steps
1. Lower column cover 75w<
2. Upper column cover 1 16Wl695
3. Cable band
4. I nition switch NOTE
5. It ey remind switch Reverse the removal procedures to reinstall.

INSPECTION
(1) Disconnect the wiring connector from the ignition switch,
and connect an ohmmeter to the switch side connector.
(2) Operate the switch, and check the continuity between
Key reminder switch the terminals.

Removed
LOCK

ACC o--o
Inserted o-0
ON 0 -0
START 0 -0

NOTE
O-O indicates that there is continuity between the
16UO360
terminals.

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