Starter - Reduction Gear Geo Storm I

DESCRIPTION

Nippondenso and Mitsubishi starters are solenoid-actuated gear reduction type. Starters are equipped with overrunning clutch/drive assembly. The brush holder assembly retains 4 brushes and springs in the commutator end of starter housing. The integral starter solenoid is attached to the drive housing. All vehicles use some type of clutch start (M/T) or neutral safety (A/T) switch incorporated within starter wiring circuit. Prizm and Storm use relays in starter wiring circuit.

TROUBLE SHOOTING

Note. See the TROUBLE SHOOTING - BASIC PROCEDURES article in the GENERAL TROUBLE SHOOTING section.

ON-VEHICLE TESTING

Note. Before testing, ensure battery is fully charged, battery cables and terminal ends are clean and tight and engine grounds are good.

CRANKING TEST

1. Connect voltmeter and ammeter to battery. (Scheme 1) Disconnect ignition coil secondary wire from distributor cap, and attach it to ground. Crank engine, and observe meters.
2. Ensure cranking voltage is at least 9.5 volts. Ensure current draw is not more than 270 amps. If readings are not as specified, replace starter.

Scheme 1

CIRCUIT TEST

If a no-start condition exists, touch test light to starter solenoid ST terminal (terminal No. 50 on Prizm). Turn ignition switch to START position. If test light does not glow, check ignition switch, relays and wiring circuit. See appropriate relay and switch tests below under ON-VEHICLE TESTING. If test light glows, remove starter, and go to BENCH TESTING .

Prizm & Storm

1. Switch is located above clutch pedal on bracket. Disconnect switch harness connector.
2. With clutch pedal depressed, check continuity between switch connector terminals using ohmmeter. Ensure continuity exists. If continuity is not present, adjust or replace switch as required.

Tracker

Disconnect switch harness, mounted to bracket above clutch pedal. With clutch pedal depressed, check continuity between switch connector terminals using ohmmeter. Ensure continuity exists. If continuity is not present, adjust or replace switch as required.

Metro

1. Switch is located on transmission shift lever. Place transmission in Park, and turn ignition switch to START position. Using test light, backprobe Black/Red wire terminal at neutral switch connector.
2. Test light should glow. If test light does not glow, repair open in Black/Red wire from neutral switch to main harness splice connector under left side of dash, near Electronic Control Module (ECM). At splice connector, Black/Red wire changes to Black/Yellow wire to complete start circuit to ignition switch.
3. With ignition switch in START position, backprobe Black/Yellow wire terminal at neutral switch connector using test light. Test light should glow. If test light does not glow, replace neutral switch.

Prizm

1. Switch is located on transmission shift lever. Place transmission in Park, and turn ignition switch to START position. Using test light, backprobe Black/White wire terminal at neutral switch connector. Test light should glow. If test light does not glow, repair open in Black/White wire circuit to ignition switch.
2. Turn ignition switch to START position. Using test light, backprobe Black wire terminal at neutral switch connector. Test light should glow. If test light does not glow, replace neutral switch.

1. Switch is located on transmission shift lever. Place transmission in Park, and turn ignition switch to START position. Using test light, backprobe Black/Red wire terminal at neutral switch connector. Test light should glow. If test light does not glow, repair open in Black/Red wire circuit to ignition switch.
2. Turn ignition switch to START position. Using test light, backprobe Black/Yellow wire terminal at neutral switch connector. Test light should glow. If test light does not glow, replace neutral switch.

Storm (3-Speed A/T)

1. Relay is located in relay box on right side of engine compartment. Ensure transmission is in Park and ignition switch is in START position. Using test light, backprobe Black/White wire and White/Blue wire terminals at neutral relay. Test light should glow. If test light does not glow, repair open in Black/White wire circuit to ignition switch and/or open in White/Blue wire circuit to Park/Neutral switch.
2. Turn ignition switch to START position. Using test light, backprobe Black/Orange wire terminal at neutral relay. Ensure test light glows. If test light does not glow, check Black wire of neutral relay to ground. Ground connection is located at front of right inner fender panel, near front of fuse box. If ground is okay, replace neutral relay.

1. Switch is located on transmission, near manual shift lever. Switch harness connector is on left fender. Ensure transmission is in Park and ignition switch is in START position.
2. Using test light, backprobe White/Blue wire terminal of switch harness connector. If test light glows with ignition switch in START position, switch is okay.
3. If test light does not glow, backprobe Black/Yellow wire terminal of switch harness connector. If test light glows with ignition switch in START position, adjust or replace switch as required.

Storm GSi (4-Speed A/T)

1. Switch and harness connector are located on top of transmission, next to manual shift linkage. Ensure transmission is in Park and ignition switch is in START position.
2. Using test light, backprobe Black/Orange wire terminal of switch connector. If test light glows, switch is okay.
3. If test light does not glow, backprobe Black/White wire terminal of switch connector with ignition switch in START position. If test light glows, adjust or replace switch as required.

Prizm (M/T)

1. Relay is located at top of interior fuse/relay block, at left kick panel. Remove relay. Using ohmmeter, check continuity between terminals No. 1 and 3 (STEP 1). (Scheme 2) Ensure continuity is present. If continuity is not present, replace relay.
2. Check continuity between terminals No. 2 and 4 (STEP 1). (Scheme 2) Continuity should not be present. If continuity is present, replace relay.
3. Operate relay by applying 12 volts to terminal No. 1 and grounding terminal No. 3. Check continuity between terminals No. 2 and 4 (STEP 2). (Scheme 2) Ensure continuity is present. If continuity is not present, replace relay.

Scheme 2

Storm

1. Relay is located in fuse/relay box, on left side of engine compartment. Remove relay. Using ohmmeter, check continuity between terminals No. 1 and 5. (Scheme 3) Ensure continuity is present. If continuity is not present, replace relay.
2. Check for continuity between terminals No. 2 and 3. (Scheme 3) Ensure continuity exists. If continuity is not present, replace relay.
3. Check continuity between terminals No. 4 and 6 and between terminals No. 2 and 6. Continuity should not be present. If continuity exists, replace relay.
4. Energize relay by applying battery voltage to terminal No. 1 and grounding terminal No. 5. Check continuity between terminals No. 2 and 3 and between terminals No. 4 and 6. Ensure continuity exists. If continuity is not present, replace relay.

Scheme 3

1. Using test light, backprobe White/Green wire terminal of ignition switch 5-terminal connector. Connector is located on right of junction block, under left dash panel. Test light should glow.
2. If test light does not glow, check fusible links "A" and "B". Fusible link box is located behind battery. Check for open in White/Green wiring circuit to ignition switch. See appropriate chassis wiring diagram in the WIRING DIAGRAMS section.
3. Turn ignition switch to START position. Using a test light, backprobe Black/Yellow wire terminal (at ignition switch 9-terminal connector) to starter circuit and Black/Blue wire terminal to ignition power circuit. Test light should glow. If test light does not glow at either terminal, replace ignition switch.

1. Using test light, backprobe Black/Red wire terminal of ignition switch 8-terminal connector. Connector is located behind lower instrument panel. Test light should glow.
2. If test light does not glow, check fusible link AM2. Fusible link box is located on positive battery cable. Check for open in Black/Red wiring circuit to ignition switch. See appropriate chassis wiring diagram in the WIRING DIAGRAMS section.
3. Turn ignition switch to START position. Using a test light, backprobe Black/White wire terminal (at ignition switch 8-terminal connector) to starter circuit and Blue/Red wire terminal to ignition power circuit. Test light should glow. If test light does not glow at either terminal, replace ignition switch.

1. Using test light, backprobe White/Black wire terminal of ignition switch 8-terminal connector. Connector is located on steering column, near ignition switch. Test light should glow.
2. If test light does not glow, check main and key fuses. Check for open in White/Black wiring circuit to ignition switch. See appropriate chassis wiring diagram in the WIRING DIAGRAMS section.
3. Turn ignition switch to START position. Using a test light, backprobe Black/White wire terminal (at ignition switch 8-terminal connector) to starter circuit and Black/Yellow wire terminal to ignition power circuit. Test light should glow. If test light does not glow at either terminal, replace ignition switch.

1. Using test light, backprobe White/Green wire terminal of ignition switch 7-terminal connector. Connector is located behind lower instrument panel, near steering column. Test light should glow.
2. If test light does not glow, check fusible link "B". Fusible link box is located on right inner fender. Check for open in White/Green wiring circuit to ignition switch. See appropriate chassis wiring diagram in the WIRING DIAGRAMS section.
3. Turn ignition switch to START position. Using a test light, backprobe Black/Yellow wire terminal (at ignition switch 7-terminal connector) to starter circuit and Blue wire terminal to ignition power circuit. Test light should glow. If test light does not glow at either terminal, replace ignition switch.

NO-LOAD TEST

1. Remove starter. Connect ammeter in series with starter motor and fully charged 12-volt battery. (Scheme 4) Connect voltmeter to battery to observe voltage draw readings.
2. Connect remote starter or jumper wire to battery and start terminal of solenoid. Crank starter for maximum of 5 seconds. Starter drive pinion should extend completely and quickly. Starter should spin smoothly at 3000 RPM or more. Current draw should be less than 90 amps at about 11.5 volts.

Scheme 4

Note. Following solenoid tests must be performed with starter assembled and field lead disconnected from starter at solenoid.

SOLENOID PULL-IN COIL TEST

1. Disconnect field lead from solenoid field lead terminal. (Scheme 5) Ensure field lead does not touch starter housing. Connect negative lead of 12-volt battery to solenoid field lead terminal (terminal "C"). On Prizm (Scheme 7)or (Scheme 8) for terminal "C" location.
2. Connect another negative battery lead to starter drive housing. Connect positive battery lead to solenoid ST terminal (terminal No. 50 on Prizm). (Scheme 5)
3. Pinion gear should extend quickly and completely when solenoid is energized. If pinion gear does not operate as indicated, replace solenoid.

Scheme 5

SOLENOID HOLD-IN COIL TEST

After pull-in coil tests okay, disconnect negative battery lead from solenoid field lead terminal (terminal "C"). Pinion gear should remain extended. If pinion gear does not operate as indicated, replace solenoid.

Brushes & Springs

1. Measure brush length, and replace brushes if less than specification. See «MINIMUM BRUSH LENGTH SPECIFICATIONS»(/geo/storm/i-1990-1993/remont/starter/#starter-reduction-gear) . Check brush springs for corrosion or damage. Ensure spring tension is sufficient to press brushes against commutator.
2. Check condition of brush holders, spring clips and insulation between positive and negative holders. Repair or replace as required. Ensure brushes move freely in holders. Before installing new brushes, buff commutator end of brush using emery cloth.

MINIMUM BRUSH LENGTH SPECIFICATIONS

Commutator

1. Using "V" blocks and dial indicator, check commutator runout (out-of-round). Ensure runout is not more than .002"(.05 mm). Turn commutator/armature on lathe until runout (out-of-round) is within specification.
2. Check diameter commutator. Commutator should not be less than specification. See «MINIMUM COMMUTATOR SPECIFICATIONS»(/geo/storm/i-1990-1993/remont/starter/#starter-reduction-gear) . If commutator is cut down more than .008" (.20 mm), undercut insulating mica to depth of .015-.031" (.38 -.78 mm).

MINIMUM COMMUTATOR SPECIFICATIONS

Armature Coil

1. Using ohmmeter, check continuity between armature core and insulation between commutator segments. No continuity should be present. If continuity is not present, check armature for shorts using a growler. Replace armature as required.
2. Ensure continuity exists between segments on commutator. If continuity is not present between any 2 segments, replace armature.

Field Coil

Check field coils in housing for open circuits. Ensure continuity exists between field lead wire and field coil brush lead. If continuity is not present, replace field coil. Check field coils for short circuits. If shorts exist, replace defective field coil.

OVERHAUL

Overhaul information is not available. Refer to the figures for disassembly and reassembly reference. (Scheme 6)- (Scheme 11).

Scheme 6

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Scheme 11

TORQUE SPECIFICATIONS

STARTER MOUNTING BOLT TORQUE SPECIFICATIONS

See also:
• TROUBLE SHOOTING - BASIC PROCEDURES
• BENCH TESTING