Starters: Diagnosis Honda Pilot I

STARTER CIRCUIT TROUBLE SHOOTING

Note. Air temperature must be between 59° and 100°F (15° and 38°C) during this procedure. After this test, or any subsequent repair, reset the Engine Control Module (ECM)/Powertrain Control Module (PCM) to clear any codes. See appropriate TESTING & DIAGNOSTICS article in ENGINE PERFORMANCE. The battery must be in good condition and fully charged.

STARTER SOLENOID TEST

1. 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. (Scheme 1)
2. 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.

Scheme 1

STARTER PERFORMANCE TEST

1. Disconnect the wires from the "S" terminal and the "M" terminal. (Scheme 1)
2. Make the connections as described below 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.
3. Connect the battery. (Scheme 2) Be sure to disconnect the starter motor wire from the solenoid. If the starter pinion moves out, it is working properly.
4. Disconnect the battery from the "M" terminal. If the pinion does not retract, the hold-in coil of the solenoid is working properly. (Scheme 3)
5. Disconnect the battery from the starter body. If the pinion retracts immediately, it is working properly. (Scheme 4)
6. Clamp the starter firmly in a vise.
7. Connect the starter to the battery, and confirm that the motor starts and keeps rotating. (Scheme 5)
8. If the electric current and motor speed meet the specifications when the battery voltage is at 11.5 V, the starter is working properly. See «STARTER PERFORMANCE TEST SPECIFICATIONS»(ref-164164-S40962603832004072600000).

STARTER PERFORMANCE TEST SPECIFICATIONS

Scheme 2

Scheme 3

Scheme 4

Scheme 5

ARMATURE TEST

1. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage, replace the armature. (Scheme 6)
2. Check the commutator (A) surface. If the surface is dirty or burnt, resurface with emery cloth or a lathe within the following specifications, or recondition with # 500 or # 600 sandpaper (B). (Scheme 7)
3. Check the commutator diameter. See «STARTER SPECIFICATIONS»(ref-164164-S34004169152004072600000). If the diameter is below the service limit, replace the armature. (Scheme 8)
4. Measure the commutator runout. See «STARTER SPECIFICATIONS»(ref-164164-S34004169152004072600000). 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. (Scheme 9)
5. 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). (Scheme 10)
6. Check for continuity between the segments of the commutator. If an open circuit exists between any segments, replace the armature. (Scheme 11)
7. 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. (Scheme 12)
8. Check with an ohmmeter that no continuity exists between the commutator (A) and armature coil core (B), and between the commutator and armature shaft (C). If continuity exists, replace the armature. (Scheme 13)

Scheme 6

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Scheme 11

Scheme 12

Scheme 13

BRUSH HOLDER TEST

1. Using an ohmmeter, check continuity between positive and negative brush holders (brackets). (Scheme 14) Continuity should not exist. If continuity exists, brush holder assembly is shorted and must be replaced.
2. Measure brush length. If it is not within the service limit, replace the brush holder assembly. (Scheme 15)

Scheme 14

Scheme 15

BRUSHES & SPRING TEST

Insert the brush (A) into the brush holder, and bring the brush into contact with the commutator, attach a spring scale (B) to the spring (C). Measure the spring tension at the moment the spring lifts off the brush. (Scheme 16) If the spring tension is not within specification, replace the spring. See STARTER SPECIFICATIONS.

Scheme 16

OVERRUNNING CLUTCH TEST

1. Slide overrunning clutch along shaft. If overrunning clutch does not slide smoothly, replace overrunning clutch assembly. Rotate overrunning clutch on shaft. (Scheme 17) If clutch does not lock when rotated in one direction and rotates smoothly in other direction, replace overrunning clutch assembly.
2. Check starter drive gear for wear or damage. If gear is damaged, replace overrunning clutch assembly. Drive gear is not available separately. Check starter drive gear teeth for wear or damage. If starter drive gear teeth are damaged, check condition of flywheel (M/T) or flexplate (A/T).
3. Reassemble the starter in the reverse order of removal.

Scheme 17