Starting System: Diagnosis Honda Insight ZE2 рестайлинг

Symptom Troubleshooting Index

Scheme 2

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 this inspection, you must reset PGM-FI ECU in the PGM-FI INSPECTION menu with the HDS to cancel ALL INJECTORS STOP and STARTER TEST functions. The 12 V battery must be in good condition and fully charged.

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1. Connect the alternator, regulator, battery, and starter tester (OTC 3131) 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 LOW CHARGE? YES -The battery is OK. Charge the battery if necessary, then go to step 3. 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 HDS to the DLC (see step 2 on «GENERAL TROUBLESHOOTING INFORMATION»(ref-513169-S26774795252012110700000) ).
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 with the PCM, troubleshoot the DLC circuit (see «DLC CIRCUIT TROUBLESHOOTING»(ref-513153-S33429882062012110700000) ).
6. Select ALL INJECTORS STOP in the PGM-FI INSPECTION menu with the HDS.
7. Select STARTER TEST in the PGM-FI INSPECTION menu with the HDS.
8. Set the parking brake, then with the shift lever in P or N, 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 step 17 . NO -Go to step 9.
9. Turn the ignition switch to LOCK (0).
10. 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 step 17 . NO -Based on the following symptoms, take the appropriate action: If the starter does not crank the engine at all, go to step 11. If the starter cranks the engine erratically or too slowly, go to step 14 . If the starter does not disengage from the torque converter ring gear when you release the key, replace the starter (see «STARTER REMOVAL AND INSTALLATION»(ref-513167-S34630448412012110700000) ), or remove and disassemble it (see «STARTER OVERHAUL»(ref-513167-S36837556622012110700000) ), and check for the following. Starter solenoid and switch malfunction Dirty drive gear or damaged overrunning clutch Damaged torque converter ring gear
11. Remove the air cleaner (see «AIR CLEANER REMOVAL/INSTALLATION»(ref-513163-S20686336082012110700000) ).
12. Make sure the shift lever is in P or N, and set the parking brake, then disconnect the connector (A) from the starter S terminal (B). Connect a jumper wire from the battery positive terminal to the S terminal. Does the starter crank the engine? YES -Go to step 13. NO -Remove the starter (see «STARTER REMOVAL AND INSTALLATION»(ref-513167-S34630448412012110700000) ), and repair or replace (see «STARTER OVERHAUL»(ref-513167-S36837556622012110700000) ) it as necessary.
13. Check the following items in the order listed until you find the problem in the circuit. NOTE: After the problem in the circuit is found and repaired, go to step 17 . Check the No. 44 (7.5 A) fuse in the under-dash fuse/relay box. Check for an open or short in the RED wire and connectors between the under-dash fuse/relay box and the ignition switch. Check for an open or short in the BLU wire and connectors between the under-dash fuse/relay box and the PCM. Check for an open or short in the LT GRN wire and connectors between the under-dash fuse/relay box and the PCM. Check for an open or short in the BRN wire, BLK/WHT wire, and connectors between the under-dash fuse/relay box and the starter. Check for an open or short in the RED/BLK wire and connectors between the transmission range switch and the PCM. Check for an open or short in the BLU/BLK wire and connectors between the transmission range switch and the PCM. Check for poor connections or loose terminals at the transmission range switch and body ground (G101). Check for a faulty ignition switch (see «PARK PIN SWITCH TEST»(ref-513171-S03396872012012110700000) ). Check for a faulty starter cut relay (see «POWER RELAY TEST»(ref-513170-S00592820692012110700000) ). Check for a faulty transmission range switch (see «TRANSMISSION RANGE SWITCH TEST»(ref-513160-S30007462352012110700000) ).
14. Connect the alternator, regulator, battery, and starter tester to the battery. NOTE: The probe is not used for battery testing.
15. Do the STARTING TEST. Does the display indicate cranking voltage greater than or equal to 8.5 V and is the current draw less than or equal to 350 A? YES -Go to step 16. NO -Replace the starter (see «STARTER REMOVAL AND INSTALLATION»(ref-513167-S34630448412012110700000) ), or remove and disassemble it (see «STARTER OVERHAUL»(ref-513167-S36837556622012110700000) ), and check for these problems: Drag in the starter armature Shorted armature winding Excessive drag in the engine Open circuit in starter armature commutator segments Excessively worn starter brushes Open circuit in starter brushes Dirty or damaged helical splines or drive gear Faulty overrunning clutch
16. Remove the starter (see «STARTER REMOVAL AND INSTALLATION»(ref-513167-S34630448412012110700000) ), and inspect its drive gear and the torque converter ring gear for damage. Replace any damaged parts.
17. Select PGM-FI ECU reset (see «IF THE MIL DID NOT STAY ON»(ref-513169-S20882293332012110700000) ) in the PGM-FI INSPECTION menu with the HDS to cancel ALL INJECTORS STOP and STARTER TEST.
18. If the IMA battery level indicator displays no level, start the engine, and hold the engine speed between 3, 500 and 4, 000 rpm without load (in P or N) until the level in the indicator is half full.
19. Install the air cleaner (see «AIR CLEANER REMOVAL/INSTALLATION»(ref-513163-S20686336082012110700000) ).

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1. Remove the starter (see «STARTER REMOVAL AND INSTALLATION»(ref-513167-S34630448412012110700000) ).
2. Clamp the starter firmly in a vise.
3. 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.
4. Connect the battery as shown, and check for continuity between the B terminal and the starter body. If there is continuity, it is working properly.
5. Disconnect the battery from the starter body as shown, and check for continuity between the B terminal and the starter body. If there is no continuity, it is working properly.
6. Connect the starter to the battery as shown, and confirm that the motor runs.
7. If the electric current meets the specification when the battery voltage is at 11.5 V, the starter is working properly. Specification Electric Current: 80 A or less

Scheme 9

1. Do the 12 volt battery terminal disconnection procedure (see «USING THE GR8 BATTERY DIAGNOSTIC STATION»(ref-513168-S03188703672012110700000) ).
2. Remove the air cleaner (see «AIR CLEANER REMOVAL/INSTALLATION»(ref-513163-S20686336082012110700000) ).
3. Disconnect the positive starter cable (A) and the harness connector (B) from the S terminal, then remove the heater hose bracket (C).
4. Remove the two bolts securing the starter, then remove the starter.

Scheme 10

1. Install the starter, then tighten the starter mounting bolts (A).
2. Connect the positive starter cable (B) and the harness connector (C) to the S terminal, then install the heater hose bracket (D). Make sure the crimped side of the ring terminal is facing out.
3. Install the air cleaner (see «AIR CLEANER REMOVAL/INSTALLATION»(ref-513163-S20686336082012110700000) ).
4. Do the 12 volt battery terminal reconnection procedure (see «USING THE GR8 BATTERY DIAGNOSTIC STATION»(ref-513168-S03188703672012110700000) ).

Scheme 11

Note. Refer to the (Scheme 11) if needed during this procedure.

Armature Inspection and Test

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1. Remove the starter (see «STARTER REMOVAL AND INSTALLATION»(ref-513167-S34630448412012110700000) ).
2. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage, replace the armature.
3. Check the commutator (A) surface. If the surface is dirty or burnt, resurface it with an emery cloth or a lathe to the specification in step 4, or recondition with #500 or #600 sandpaper (B).
4. Check the commutator (A) diameter with a digital caliper or dial type caliper. If the diameter is below the service limit, replace the armature. Commutator Diameter Standard (New): 28.0-28.1 mm (1.102-1.106 in) Service Limit: 27.5 mm (1.083 in)
5. 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)
6. 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): 0.40-0.50 mm (0.0157-0.0197 in) Service Limit: 0.15 mm (0.0059 in)
7. 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.
8. 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.
9. 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. Starter Brush Inspection
10. 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 (0.437-0.453 in) Service Limit: 4.3 mm (0.169 in) Starter Brush Holder Test
11. Check for continuity between the (+) brushes (A) and the (-) brushes (B). If there is continuity, replace the brush holder assembly. Planetary Gear Inspection
12. Check the planetary gears (A), the armature shaft gear (B), and the internal ring gear (C). Replace them if they are worn or damaged. Overrunning Clutch Inspection
13. 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 set.
14. 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 set.
15. If the 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 drive gear teeth are damaged. Starter Reassembly
16. 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.
17. While squeezing a brush spring (C), insert it in the hole on the brush holder, and push it until it bottoms. Repeat this for the other three brush springs (D, E, and F).
18. Install the armature and brush holder assembly into the armature housing.

Note. Make sure the armature stays in the holder.