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SECTION

UNIT REPAIR



M3C11E16
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Starter Motor

Inspection / Measurement (Before the Overhaul)

  1. Remove the starter. Refer to "Starter" in this section.
  2. Pinion clearance inspection.
  3. Notice : Complete the testing in a minimum amount of time to prevent overheating and damaging the solenoid. (in 10 seconds)



    M3C11E17
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    M3C11E18
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  4. Magnetic switch pull-in test.
  5. Notice : Complete the testing in a minimum amount of time to prevent overheating and damaging the solenoid. (in 10 seconds)



    M3C11E19
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    M3C11E20
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  6. Solenoid hold-in test.
  7. Notice : Complete the testing in a minimum amount of time to prevent overheating and damaging the solenoid.



    M3C11E21
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    M3C11E22
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  8. Solenoid return test.
  9. Notice : Complete the testing in a minimum amount of time to prevent overheating and damaging the solenoid.



    M3C11E23
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    M3C11E24
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  10. No-road test.


  11. M3C11E25
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    Desciption
    Limit
    The speed of pinion gear
    Minimum : 2,000 rpm
    Condition :
    Voltage / Current
    Maximum : 9V / 150A


M3C11E26
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Disassembly Procedure

  1. Remove the starter contact end frame.


  2. M3C11E27
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  3. Remove the brush holder assembly.


  4. M3C11E28
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  5. Remove the field frame assembly from the armature set (1).


  6. M3C11E29
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  7. Remove the solenoid assembly.


  8. M3C11E30
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  9. Remove the armature set and solenoid from the starter housing.


M3C11E31
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Inspection / Measurement (After the Overhaul)

  1. Ground test for armature coil.


  2. M3C11E32
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  3. Short circuit test for armature coil.


  4. M3C11E33
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  5. Open circuit test for armature coil.


  6. M3C11E34
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  7. Inspect the brushes wear.
  8. Brushes wear limit.
    Desciption
    Standard
    Limit
    Brushes wear
    11.3-11.5 mm
    (0.445-0.453 in)
    7.0-7.25 mm
    (0.275-0.285 in)


M3C11E35
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Assembly Procedure

  1. Install in the reverse order of removal.
  2. Install the bolts / nuts.
  3. Tighten
    Tighten the starter motor terminal M nut to 9-12 N•m (80-106 lb-in) (a).
    Tighten the through-bolts to 4-6 N•m (35-53 lb-in) (b).



M3C11E36
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Generator (DAC)

Disassembly Procedure

  1. Remove the generator. Refer to "Generator" in this section.
  2. Remove the cover from the generator.
  3. Cover.


    M3C11E37
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  4. Remove the regulator / brush holder / rectifier assembly.


  5. M3C11E38
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    M3C11E39
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  6. Remove the regulator / brush holder / rectifier.
  7. a. Rectifier.
    b. Regulator.
    c. Brush holder.


    M3C11E40
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  8. Remove the shield before the drive end bracket and the frame.


  9. M3C11E41
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  10. Remove the pulley and rotor assembly from the drive end bracket.


  11. M3C11E42
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  12. Remove the drive end bracket, rotor and space.


  13. M3C11E43
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  14. Remove the stator assembly from the frame.


M3C11E44
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Inspection / Measurement

  1. Inspect the rotor assembly.


  2. M3C11E45
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    M3C11E46
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  3. Inspect the stator.


  4. M3C11E47
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    M3C11E48
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  5. Inspect the rectifier.
  6. Positive rectifier test: Inspect the open circuit for stator coil lead terminals using the ohmmeter (1).
    Replace the rectifier if necessary.


    M3C11E50
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  7. Inspect trio diodes.
  8. Replace the heat sink if necessary (a).


    M3C11E51
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  9. Inspect the brush wear
  10. a. Brush wear limit.
    Desciption
    Standard
    Limit
    Brushes wear
    20 (0.79)
    14 (0.55)


M3C11E52
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Assembly Procedure

  1. Install in the reverse order of removal.
  2. Install the screws / nuts / bolts.
  3. Tighten



    M3C11E53
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    M3C11E54
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    M3C11E55
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SCHEMATIC AND ROUTING DIAGRAMS

Starting System


M3C11E56
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Charging System


M3C11E57
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SPECIFICATIONS

Starter Specifications

Application
Description
Unit
Standard
Limit
Starter Motor
Type
-
SD 80
-
Output (Capacity)
kW
0.8
-
No Load Test @ 9 volts Drive Pinion Speed
A
RPM
150
2,000
-
Brushes Length
mm (in.)
11.3-11.5
(0.445-0.453)
7.0-7.25
(0.275-0.285)

Generator Specifications

Application
Description
Unit
Standard
Limit
Generator
Type
-
CS114D (DAC)
-
Regulator Voltage
V
14.3-4.9
-
Brushes Length
mm (in.)
20.0 (0.787)
14 (0.551)
Output (Capacity)
-
12V, 65A
(0.445-0.453)
-

Battery Specifications

Application
Description
Unit
Standard
Limit
Battery
Type
-
MF
-
Capacity
AH
45
-
Cold Cranking Amps
CCA
330
-

Fastener Tightening Specifications

Application
N•m
Lb-Ft
Lb-In
Distributor Bolts
10 - 16
-
89 - 142
Battery Retainer Clamp-to-Battery Rod Nuts
6 - 8
-
53 - 71
Battery Carrier Tray Bolts
9 - 12
-
80 - 106
Battery Cable Nuts
9 - 12
-
80 - 106
Starter field Connector Nut
9 - 12
-
80 - 106
Starter Through-Bolts
4 - 6
-
35 - 53
Starter Mounting Bolts
55 - 65
41 - 48
-
Starter Solenoid Assembly Screws
6 - 8
-
53 - 71
Starter Solenoid Nuts
9 - 12
-
80 - 106
Spark Plug
20 - 30
15 - 22
-
Generator Through-Bolts
4 - 6
-
35 - 53
Generator Drive End Nut
80 - 110
59 - 81
-
Generator Battery Lead Connector Nut
4 - 7
-
35 - 62
Generator Bearing Plate Bolt
6 - 8
-
53 - 71
Generator Brush Holder / Rectifier Screw
9 - 12
-
80 - 106
Generator Belt Tension Adjusting Bolt
18 - 28
13 - 21
-
Generator Shackle Bracket Bolt
45 - 55
33 - 41
-
Generator Lower Bracket-to-Generator Bolt/Nut
18 - 28
13 - 21
-
Ground Bolt
35 - 41
26 - 30
-
Ignition Coil Screw
4 - 7
-
35 - 62
Ignition Coil Bracket Bolt
9 - 12
-
80 - 106


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