Starting System: Diagnosis Honda Element I

Symptom Troubleshooting Index

SYMPTOM TROUBLESHOOTING INDEX

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Starter Circuit Troubleshooting

Note. Air temperature must be between 59 and 100°F (15 and 38° After this inspection, you must reset the engine control module (ECM)/powertrain control module (PCM), otherwise the ECM/PCM will continue to stop the fuel injectors from working. Select ECM/PCM reset using the Honda Diagnostic System (HDS) (see HDS CLEAR COMMAND ). The battery must be in good condition and fully charged.

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1. Hook up the following equipment: Ammeter, 0-400 A Voltmeter, 0-20 V (accurate within 0.1 V)
2. Connect the HDS to the data link connector (DLC) (see step 2 on «HOW TO USE THE HDS (HONDA DIAGNOSTIC SYSTEM)»(ref-220569-S09637220872006022000000) ).
3. Turn the ignition switch ON (II), select PGM-FI, INSPECTION, then ALL INJECTORS OFF on the HDS.
4. With the shift lever in N or P (A/T) or the clutch pedal pressed (M/T), turn the ignition switch to START (III). Does the starter crank the engine normally? YES - The starting system is OK. Go to step 10 . NO - Go to step 5.
5. Check the battery condition. Check electrical connections at the battery, the negative battery cable to body, the engine ground cables, and the starter for looseness and corrosion. Then try cranking the engine again. Does the starter crank the engine? YES - Repairing the loose connection corrected the problem. The starting system is OK. Go to step 10 . NO - Check the following: If the starter will not crank the engine at all, go to step 6. If it cranks the engine erratically or too slowly, go to step 7 . If it won't disengage from the flywheel or torque converter ring gear when you release the key, check for the following until you find the cause. Solenoid plunger and switch malfunction Dirty drive gear or damaged overrunning clutch
6. Make sure the transmission is in Neutral, then disconnect the BLK/WHT wire from the starter solenoid S terminal. Connect a jumper wire from the battery positive terminal to the solenoid terminal. M/T A/T Does the starter crank the engine? YES - Check the following items in the order listed until you find the open circuit: Check the BLK/WHT wire and connectors between the under-dash fuse/relay box and the ignition switch, and between the under-dash fuse/relay box and the starter. Check the ignition switch (see «TEST»(ref-220621-S26579580532006022100000) ). Check the transmission range switch and connector (A/T) or the clutch interlock switch and connector (M/T). Check the starter cut relay (see «POWER RELAY TEST»(ref-220620-S08922687602006022100000) ). NO - Remove the starter, and repair or replace as necessary.
7. Check the cranking voltage and current draw. Is the cranking voltage greater than or equal to 7.7 V (M/T)/8.5 V (A/T) and is the current draw less than or equal to 400 A (M/T)/380 A (A/T)? YES - Go to step 8. NO - Replace the starter, or remove and disassemble it, and check for the following until you find the cause: Drag in the starter armature Shorted armature winding Excessive drag in the engine
8. Check the engine speed while cranking the engine. Is the engine speed above 100 RPM? YES - Go to step 9. NO - Replace the starter, or remove and disassemble it, and check for the following until you find the cause: Open circuit in starter armature commutator segments Excessively worn starter brushes Open circuit in commutator brushes Dirty or damaged helical splines or drive gear Faulty drive gear clutch
9. Remove the starter, and inspect its drive gear and the flywheel or torque converter ring gear for damage. Replace any damaged parts.
10. Select ECM/PCM reset (see «ECM/PCM RESET»(ref-220569-S34002765082006022000000) ) to cancel ALL INJECTORS OFF on the HDS.

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1. Disconnect the clutch interlock switch 2P connector (A).
2. Remove the clutch interlock switch (B).
3. Check for continuity between the terminals according to the table. If the continuity is not as specified, replace the clutch interlock switch. If OK, install the clutch interlock switch, and adjust the pedal height (see «CLUTCH PEDAL, CLUTCH PEDAL POSITION SWITCH, AND CLUTCH INTERLOCK SWITCH ADJUSTMENT»(ref-220578-S28193432382006022000000) ).

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1. Make sure you have the anti-theft code for the radio, then write down the customer's audio presets.
2. Disconnect the negative cable from the battery first, then disconnect the positive cable.
3. Remove the starter cable (A), BLK/WHT wire (B), and motor cable (C).
4. 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 step 5. If there is no continuity, replace the solenoid.
5. Check the pull-in coil for continuity between the S terminal and M terminal. There should be continuity. If there is continuity, the solenoid is OK. If there is no continuity, replace the solenoid.
6. Install the reverse order of removal.
7. Connect the positive cable to the battery first, then connect the negative cable.
8. Enter the anti-theft code for the radio, then enter the customer's audio presets.
9. Do the power window control unit reset procedure (see «RESETTING THE POWER WINDOW CONTROL UNIT»(ref-220630-S35739607722006022100000) ).
10. Set the clock.

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1. Disconnect the wire from the M terminal.
2. Make a connection as shown using as heavy a wire as possible (preferably equivalent to the wire used for the vehicle). NOTE: To avoid damaging the starter, never leave the battery connected for more than 10 seconds.
3. Connect the battery as shown. Make sure you disconnect the starter motor wire from the solenoid. If the starter pinion moves out, it is working properly.
4. Disconnect the negative battery terminal from the M terminal as shown. If the pinion does not retract, the hold-in coil of the solenoid is working properly.
5. Disconnect the negative battery terminal from the starter body as shown. If the pinion retracts immediately, it is working properly.
6. Firmly clamp the starter in a vise.
7. Reconnect the wire to the M terminal.
8. Connect the starter to the battery as shown in the diagram, and check that the motor starts and keeps rotating.
9. If the electric current and motor speed meet the specifications when the battery voltage is at 11 V, the starter is working properly. Specifications Electric Current: 90 A or less Motor Speed: 2,000 RPM or more

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1. Connect the battery to the starter as shown using as heavy a wire as possible (preferably equivalent to the wire used for the vehicle). To avoid damaging the starter, never leave the battery connected for more than 10 seconds.
2. If the starter pinion moves out, it is working properly.
3. Disconnect the negative battery terminal from the starter as shown. If the pinion retracts immediately, it is working properly.
4. Firmly clamp the starter in a vise.
5. Connect the starter to the battery as shown, and check that the motor starts and keeps rotating.
6. If the electric current and motor speed meet the specifications when the battery voltage is at 11.5 V, the starter is working properly. Specifications Electric Current: 80 A or less Motor Speed: 2,300 RPM or more

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1. Make sure you have the anti-theft code for the radio, then write down the customer's audio presets.
2. Disconnect the negative cable from the battery first, then disconnect the positive cable.
3. Remove the intake manifold (see «INTAKE MANIFOLD REMOVAL AND INSTALLATION»(ref-220566-S07873197532006022000000) ).
4. Disconnect the starter cable (A) from the B terminal, then disconnect the BLK/WHT wire (B) from the S terminal. M/T A/T
5. Remove the harness clamp (C).
6. Remove the harness holder (D).
7. Remove the two bolts holding the starter, then remove the starter.

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1. Install the starter, then install the harness holder (A) and the harness clamp (B), connect the starter cable (C) and BLK/WHT wire (D). Make sure the starter cable crimped side of the ring terminal is facing out. M/T A/T
2. Install the intake manifold (see «INTAKE MANIFOLD REMOVAL AND INSTALLATION»(ref-220566-S07873197532006022000000) ).
3. Connect the battery positive cable to the battery first, then connect the negative cable.
4. Start the engine to make sure the starter works properly.
5. Enter the anti-theft code for the radio, then enter the customer's audio presets.
6. Do the power window control unit reset procedure (see «RESETTING THE POWER WINDOW CONTROL UNIT»(ref-220630-S35739607722006022100000) ).
7. Set the clock.

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1. Remove the starter (see «STARTER REMOVAL AND INSTALLATION»(ref-220557-S25198420612006022000000) ).
2. Disconnect the wire from the M terminal, and remove the end cover.
3. Place a 29.4 mm (1.16 in.) outside diameter plastic pipe on the armature.
4. Move the brush holder (A) up to the pipe (B) while holding the pipe so the brushes do not pop out from the holder.

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1. 5. Disassemble the starter as shown at the beginning of this procedure.
2. 6. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage, replace the armature.
3. 7. Check the commutator (A) surface. If the surface is dirty or burnt, resurface with emery cloth or a lathe within the following specifications in step 8, or recondition with #500 or #600 sandpaper (B).
4. 8. Check the commutator diameter. If the diameter is below the service limit, replace the armature. Commutator Diameter Standard (New): 29.3-29.5 mm (1.154-1.161 in.) Service Limit: 28.8 mm (1.134 in.)
5. 9. 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): 0.05 mm (0.002 in.) max. Service Limit: 0.1 mm (0.004 in.)
6. 10. Check the mica depth (A). If the mica is too high (B), undercut the mica with a hacksaw 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). Commutator Mica Depth Standard (New): 0.40-0.60 mm (0.016-0.024 in.) Service Limit: 0.20 mm (0.008 in.)
7. 11. Check for continuity between the segments of the commutator. If there is an open circuit between any segments, replace the armature.
8. 12. 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.
9. 13. Check with an ohmmeter for continuity between the commutator (A) and armature coil core (B), and between the commutator and armature shaft (C). If there is continuity, replace the armature.

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1. 14. Measure the brush length (A). If it is shorter than the service limit, replace the brush holder assembly. Brush Length Standard (New): 7.7-8.0 mm (0.30-0.31 in.) Service Limit: 0.9 mm (0.04 in.)

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1. 15. Check for continuity between the (+) brushes (A) and (-) brushes (B). If there is continuity, replace the brush holder assembly.

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1. 16. Check the planetary gears (A) and ring gear (B) for wear or damage. Replace them if they are worn or damaged.

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1. 17. Slide the overrunning clutch (A) along the shaft. Replace it if it does not slide smoothly.
2. 18. Hold the drive gear (B), and turn the overrunning clutch in the direction shown to make sure it turns freely. Also make sure the overrunning clutch locks in the opposite direction.
3. 19. 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 flywheel ring gear to see if the starter drive gear teeth are damaged.

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1. 20. Install the armature into the housing.
2. 21. Place the brush holder assembly on the armature, then move the brush holder (A) down to the armature.
3. 22. Install the end cover to retain the brush holder.

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1. Remove the starter (see «STARTER REMOVAL AND INSTALLATION»(ref-220557-S25198420612006022000000) ).
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 with emery cloth or a lathe within the following 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. Commutator Diameter Standard (New): 28.0-28.1 mm (1.102-1.106 in.) Service Limit: 27.5 mm (1.083 in.)
6. 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 (0.001 in.) max. Service Limit: 0.05 mm (0.002 in.)
7. Check the mica depth (A). If the mica is too high (B), undercut the mica with a hacksaw 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). Commutator Mica Depth Standard (New): 0.40-0.50 mm (0.016-0.020 in.) Service Limit: 0.15 mm (0.006 in.)
8. Check for continuity between the segments of the commutator. If there is an open circuit between any 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. Check with an ohmmeter for continuity between the commutator (A) and armature coil core (B), and between the commutator and armature shaft (C). If there is continuity, replace the armature.

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1. 11. Measure the brush length. If it is shorter than the service limit, replace the brush holder assembly. Brush Length Standard (New): 11.1-11.5 mm (0.44-0.45 in.) Service Limit: 4.3 mm (0.17 in.)

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1. 12. Check for continuity between the (+) brushes (A) and (-) brushes (B). If there is continuity, replace the brush holder assembly.

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1. 13. Check the planetary gears (A) and ring gear (B) for wear or damage. Replace them if they are worn or damaged.

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1. 14. While holding the drive gear (A), turn the gear shaft (B) clockwise. Check that the drive gear comes out to the other end. If the drive gear does not move smoothly, replace the gear cover assembly.
2. 15. While holding the drive gear, turn the gear shaft counterclockwise. The gear shaft should rotate freely. If the gear shaft does not rotate smoothly, replace the gear cover assembly.
3. 16. 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 torque converter ring gear to see if the gear teeth are damaged.

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1. 17. Install the brush into the brush holder, and set the armature (A) in the brush holder (B). NOTE: To seat the new brushes, slip a strip of #500 or #600 sandpaper, with the grit side up, between the commutator and each brush, and smoothly rotate the armature. The contact surface of the brushes will be sanded to the same contour as the commutator.
2. 18. While squeezing a spring (C), insert it in the hole on the brush holder, and push it until it bottoms. Repeat this for the other three springs (D, E, and F).
3. 19. Install the armature and brush holder assembly into the housing. NOTE: Make sure the armature stays in the holder.