Starting System (V6): Diagnosis Honda Crosstour I

Symptom Troubleshooting Index

SYMPTOM TROUBLESHOOTING CHART

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Starter System Circuit Troubleshooting

Special Tools Required

Alternator, Regulator, Battery, and Starter Tester OTC3131*

*Available through the Honda Tool and Equipment Program 888-424-6857

Note. Air temperature must be within 59-100 °F (15-38 °C) during this procedure. After the inspection, you must reset the powertrain control module (PCM). Otherwise, the PCM will continue to stop the fuel injectors from operating. The battery must be in good condition and fully charged.

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1. Connect the alternator, regulator, battery and starter tester (OTC3131) to the battery as shown. NOTE: The probe is not used for battery testing.
2. Do the BATTERY TEST. Does the display indicate GOOD or GOOD, LOW CHARGE? YES -The battery is OK. Charge the battery if necessary, then go to next step. NO -If the display indicates BAD BATTERY, replace the battery, then retest. If the display indicates CHARGE & RETEST, charge the battery, then retest.
3. Connect the Honda Diagnostic System (HDS) to the data link connector (DLC).
4. Turn the ignition switch to ON (II).
5. Make sure the HDS communicates with the vehicle and the PCM. If it does not communicate, troubleshoot the DLC circuit (see «DLC CIRCUIT TROUBLESHOOTING»(ref-360057-S07895027512010042600000) ).
6. Select ALL INJECTORS STOP in the PGM-FI INSPECTION menu with the HDS.
7. Set the parking brake, then with the shift lever in N or P, turn the ignition switch to START (III) to crank the engine. Does the starter crank the engine normally? YES -The starting system is OK. Go to 15 NO -Go to next step.
8. Turn the ignition switch to LOCK (0).
9. Check the electrical connections at the battery, the negative battery cable to the body, the engine ground cables, and the starter for looseness and corrosion. Then try cranking the engine again. Does the starter crank the engine normally? YES -Repairing the loose connection corrected the problem. The starting system is OK. Go to 15 . NO -Based on the following symptoms, take the appropriate action: If the starter does not crank the engine at all, go to next step. If the starter cranks the engine erratically or too slowly, go to step 13 . If the starter does not disengage from the torque converter ring gear when you release the key, replace the starter, or remove and disassemble it, and check for the following: Starter solenoid and switch malfunction. Dirty drive gear or damaged overrunning clutch. Damage torque converter ring gear.
10. Make sure the shift lever is in N or P, then disconnect the connector (A) from the starter S terminal. Connect a jumper wire from the battery positive terminal to the S terminal. Does the starter crank the engine? YES -Go to next step. NO -Remove the starter (see «STARTER REMOVAL AND INSTALLATION»(ref-360073-S33050469092010042600000) ), then repair or replace it (see «STARTER OVERHAUL»(ref-360073-S32315203202010042600000) ) as necessary.
11. Check the following items in the order listed until you find the problem in the circuit: NOTE: After the problem in the circuit or high resistance in the circuit is found and repaired, go to step 15 . Check for an open or short in the YEL wire and connectors between the driver's under-dash fuse/relay box and the ignition switch. Check for an open or short in the WHT wire and connectors between the driver's under-dash fuse/relay box and the starter. Check for an open or short in the LT GRN wire, LT BLU wire and connectors between the driver's under-dash fuse/relay box and the transmission range switch. Check for poor ground at G101. Check for a faulty ignition switch (see «PARK PIN SWITCH TEST»(ref-360076-S16883534982010042600000) ). Check for a faulty transmission range switch (see «TRANSMISSION RANGE SWITCH TEST»(ref-360064-S40730625232010042600000) ). Check for a faulty starter cut relay (see «POWER RELAY TEST»(ref-360075-S10513756052010042600000) ).
12. Connect the alternator, regulator, battery, and started tester to the battery. NOTE: The probe is used for starter testing.
13. Do the STARTING TEST. Does the display indicate cranking voltage is greater than or equal to 8.0 V and is the current draw is less than or equal to 375 A? YES -Go to next step. NO -Replace the starter (see «STARTER REMOVAL AND INSTALLATION»(ref-360073-S33050469092010042600000) ), or remove and disassemble it (see «STARTER OVERHAUL»(ref-360073-S32315203202010042600000) ), and check for these problems: Drag in the starter armature Short in the armature winding Excessive drag in the engine Open circuit in starter armature commutator segments Excessively worn starter brushes Open circuit in the starter brushes Dirty or damaged helical splines or drive gear Faulty overrunning clutch
14. Remove the starter (see «STARTER REMOVAL AND INSTALLATION»(ref-360073-S33050469092010042600000) ), and inspect its drive gear and the torque converter ring gear for damage. Replace any damaged parts.
15. Select PCM reset (see «HDS CLEAR COMMAND»(ref-360056-S34212906112010042600000) ) in the PGM-FI INSPECTION menu to cancel ALL INJECTORS STOP with the HDS.

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1. Do the battery removal procedure (see «BATTERY REMOVAL AND INSTALLATION»(ref-360074-S11284333632010042600000) ).
2. Remove the splash separator (see step 4 on «INTAKE AIR RESONATOR REMOVAL/INSTALLATION»(ref-360066-S00912861122010042600000) ).
3. Remove the battery base (see step 11 on «ENGINE REMOVAL»(ref-360086-S10526018422010042600000) ).
4. Remove the harness clamp (A), then disconnect the positive starter cable (B), the motor wire (C), and the S terminal connector (D).
5. Check the hold-in coil for continuity between the S terminal and the armature housing (ground). There should be continuity. If there is continuity, go to next step. If there is no continuity, replace the solenoid.
6. Check the pull-in coil for continuity between the S terminal and the M terminal. There should be continuity. If there is continuity, the solenoid is OK. If there is no continuity, replace the solenoid.
7. Connect the wire and connector in the reverse order of removal.
8. Install the battery base (see step 55 on «ENGINE INSTALLATION»(ref-360086-S42449388522010042600000) ).
9. Install the splash separator (see step 4 on «INTAKE AIR RESONATOR REMOVAL/INSTALLATION»(ref-360066-S00912861122010042600000) ).
10. Do the battery installation procedure (see «BATTERY REMOVAL AND INSTALLATION»(ref-360074-S11284333632010042600000) ).

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1. Remove the starter (see «STARTER REMOVAL AND INSTALLATION»(ref-360073-S33050469092010042600000) ).
2. Install the splash seperator (see step 4 on «INTAKE AIR RESONATOR REMOVAL/INSTALLATION»(ref-360066-S00912861122010042600000) ).
3. Remove the battery base (see step 11 on «ENGINE REMOVAL»(ref-360086-S10526018422010042600000) 1).
4. Remove the harness clamp (A).
5. Disconnect the motor wire from the M terminal.
6. Clamp the starter firmly in a vise.
7. Make the connection 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 5 seconds.
8. Connect the battery as shown. Make sure you disconnect the starter motor wire from the M terminal. If the starter pinion moves out, it is working properly.
9. Disconnect the battery from the M terminal. If the pinion does not retract, the hold-in coil of the solenoid is working properly.
10. Disconnect the battery from the starter body as shown. If the pinion retracts immediately, it is working properly.
11. Reconnect the motor wire to the M terminal.
12. Connect the starter to the battery as shown, and confirm that the motor runs.
13. If the electric current meets the specification when the battery voltage is at 11.5 V, the starter is working properly. Specification Electric Current: 90 A or less

Scheme 11

1. Do the battery removal procedure (see «BATTERY REMOVAL AND INSTALLATION»(ref-360074-S11284333632010042600000) ).
2. Remove the splash separator.
3. Remove the battery base.
4. Remove the harness clamp (A).
5. Disconnect the positive starter cable (B) and the S terminal connector (C).
6. Remove the upper radiator hose bracket (D) and the dipstick (E).
7. Remove the two bolts holding the starter, then remove the starter.

Scheme 12

1. Install the starter, then tighten the mounting bolts (A). NOTE: Always use a new gasket.
2. Install the upper radiator hose bracket (B) and the dipstick (C).
3. Connect the positive starter cable (D) and the S terminal connector (E). Make sure the crimped side of the ring terminal faces away from the starter when you connect it.
4. Install the harness clamp (F).
5. Install the battery base (see page 55 on «ENGINE INSTALLATION»(ref-360086-S42449388522010042600000) ).
6. Install the splash separator (see step 4 on «INTAKE AIR RESONATOR REMOVAL/INSTALLATION»(ref-360066-S00912861122010042600000) ).
7. Do the battery installation procedure (see «BATTERY REMOVAL AND INSTALLATION»(ref-360074-S11284333632010042600000) ).
8. Start the engine to make sure the starter works properly.

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Note. Refer to the exploded view above during this procedure.

Brush Holder Removal

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1. Remove the starter (see «STARTER REMOVAL AND INSTALLATION»(ref-360073-S33050469092010042600000) ).
2. Disconnect the motor wire from the M terminal (see «STARTER PERFORMANCE TEST»(ref-360073-S35449057222010042600000) ), and remove the end cover.
3. Pry back each brush spring with a screwdriver, then position the brush on the brush holder about halfway out of its holder. Release the spring to hold it in place.
4. Remove the brush holder assembly (A). Armature Inspection and Test
5. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage, replace the armature.
6. 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 8, or recondition with #500 or #600 sandpaper (B).
7. Check the commutator diameter with a digital caliper or dial type caliper. If the diameter is below the service limit, replace the armature. Commutator Diameter Standard (New): 28.9-29.0 mm (1.138-1.142 in) Service Limit: 28.0 mm (1.102 in)
8. Measure the commutator (A) runout. If the commutator runout is within the service limit, 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. Commutator Runout Standard (New): 0.02 mm (0.0008 in) max. Service Limit: 0.05 mm (0.0020 in)
9. Use a digital caliper or dial type caliper to check the mica depth (A). If the mica depth is below the service limit, replace the armature. Commutator Mica Depth Standard (New): 0.50-0.90 mm (0.0197-0.0354 in) Service Limit: 0.20 mm (0.0079 in)
10. Use an ohmmeter to check for continuity between the segments of the commutator. If there is an open circuit between any segments, replace the armature.
11. 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 while the core is turned, the armature is shorted. Replace the armature.
12. Use an ohmmeter to check for continuity between the commutator (A) and the armature coil core (B), and between the commutator and the armature shaft (C). If there is continuity, replace the armature. Overrunning Clutch Inspection
13. Slide the overrunning clutch (A) along the shaft. Replace it if it does not slide smoothly.
14. Hold the overrunning clutch (A), and turn the drive gear (B) in the direction shown to make sure it turns freely. Also make sure the drive gear locks in the opposite direction. If it does not lock, replace the overrunning clutch assembly.
15. If the starter drive gear is worn or damaged, replace the overrunning clutch assembly; the gear is not available separately. Check the condition of the idler gear and the torque converter ring gear. Replace it if the starter drive gear teeth are damaged. Starter Brush Inspection
16. Measure the brush length. If it is shorter than the service limit, replace the brush holder assembly. Brush Length Standard (New): 15.0-16.0 mm (0.591-0.630 in) Service Limit: 9.0 mm (0.354 in) Starter Brush Holder Test
17. Check for continuity between the (+) brush holders (A) and the (-) brush holders (B). If there is continuity, replace the brush holder assembly. Brush Spring Inspection
18. Insert the brush (A) into the brush holder, and bring the brush into contact with the commutator, then attach a spring scale (B) to the spring (C). Measure the spring tension at the moment the spring lifts off the brush. If it is not within the standard, replace the brush holder assembly. Spring Tension Standard (New): 22.26-27.26 N (2.270-2.780 kgf, 5.004-6.128 lbf) Planetary Gear Inspection
19. Check the planetary gears (A), the armature shaft gear (B), and the internal ring gear (C). Replace them if they are worn or damaged. Starter Reassembly
20. Install the armature housing (A) and the armature (B) by aligning the slotted point (C) to the projection (D).
21. Pry back each brush spring with a screwdriver, then position the brush on the brush holder about halfway out of its holder. Release the spring to hold it in place. NOTE: To seat the new brushes. Slip a strip of #500 or # 600 sandpaper, with the grit side up, between the commutator and the each brush, and smoothly turn the armature. The contact surface of the brushes will be sanded to the same contour as the commutator.
22. Install the brush holder assembly. Next pry back each brush spring again, and push each brush down until it seats against the commutator, then release the spring against the end of the brush.
23. Install the end cover to retain the brush holder.