Starting System: Diagnosis Honda Pilot I рестайлинг

Symptom Troubleshooting Index

SYMPTOM TROUBLESHOOTING INDEX

Scheme 2

Starter Circuit Troubleshooting

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

Scheme 3

Scheme 4

1. Hook up the following equipment: Ammeter, 0-400 A Voltmeter, 0-20 V (accurate within 0.1 volt)
2. Connect the HDS to the data link connector (DLC) (see step 2 in «HOW TO USE THE HDS (HONDA DIAGNOSTIC SYSTEM)»(ref-243311-S31408089242006082300000) ).
3. Turn the ignition switch ON (II), and select PGM-FI, INSPECTION, then ALL INJECTORS OFF on the HDS.
4. Set the parking brake, then with the shift lever in the N or P position, 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 (see «BATTERY TEST»(ref-243308-S32108861032006082300000) ). 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 - Based on the following symptoms, take the appropriate action: 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 8 . If it 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: - Solenoid plunger and switch malfunction - Dirty drive gear or damaged overrunning clutch
6. Make sure the transmission is in Park or Neutral, and set the parking brake. Disconnect the BLK/WHT wire from the starter solenoid S terminal. Connect a jumper wire from the battery positive terminal to the solenoid terminal. Does the starter crank the engine? YES - Go to step 7 . NO - Remove the starter, and repair or replace as necessary.
7. Check the following items in the order listed until you find the open circuit: The BLK/WHT wire and connectors between the under-dash fuse/relay box and the ignition switch. The BLK/WHT wire and connectors between the under-dash fuse/relay box and the starter. The ignition switch (see «IGNITION SWITCH»(ref-243310) ). The transmission range switch and connector (see «TRANSMISSION RANGE SWITCH TEST»(ref-298124-S34358160892008091500000) ). The starter cut relay (see «POWER RELAY TEST»(ref-243309-S30998182412006082300000) ).
8. While cranking the engine, check the cranking voltage and the current draw. Is the cranking voltage greater than or equal to 7.7 V and is the current draw less than or equal to 400 A? YES - Go to step 9 . NO - Replace the starter, or remove and disassemble it, and check for the following: Drag in the starter armature Shorted armature winding Excessive drag in the engine Open circuit in starter armature commutator segments Excessive worn starter brushes Open circuit in the starter brushes Dirty or damaged helical splines or driver gear Faulty driver gear clutch
9. Remove the starter, and inspect its drive gear and torque converter ring gear for damage. Replace any damaged parts.
10. Select PCM Reset (see «PCM RESET»(ref-243311-S18398559742006082300000) ) to cancel ALL INJECTORS OFF on the HDS.

Scheme 5

1. Make sure you have the anti-theft codes for the radio and the navigation system, 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 the M terminal. There should be continuity. If there is continuity, the solenoid is OK. If there is no continuity, replace the solenoid.
6. Connect the cables and wire in the reverse order of removal.
7. Connect the negative cable to the battery.
8. Enter the anti-theft codes for the radio and the navigation system (if equipped), then enter the audio presets.
9. Do the power window control unit reset procedure (see «RESETTING THE POWER WINDOW CONTROL UNIT»(ref-243312-S03263640362006082300000) ).
10. Set the clock (on vehicles without navigation).

Scheme 6

Scheme 7

Scheme 8

Scheme 9

1. Disconnect the wire from the M terminal.
2. Make a connection as shown for this test using the thickest (gauage) wire 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 (Scheme 7) Make sure you 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.
5. Disconnect the battery from the starter body. If the pinion retracts immediately, it is working properly.
6. Clamp the starter firmly in a vise.
7. Reconnect the wire to the M terminal.
8. Connect the starter to the battery (Scheme 9), and check that the motor turns 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: 1,180 rpm or more

Scheme 10

1. Make sure you have the anti-theft codes for the radio, and the navigation system (if equipped), 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 battery.
4. Remove the automatic transmission fluid (ATF) dipstick.
5. Remove the harness clamp (A).
6. Disconnect the starter cable (B) from the B terminal, then disconnect the BLK/WHT wire (C) from the S terminal.
7. Remove the two bolts holding the starter.

Scheme 11

1. Install the starter (A) using a new gasket (B), then install the harness clamp (C), and connect the starter cable (D) to the B terminal and BLK wire (E) to the solenoid S terminal. Make sure the crimped side of the ring terminal faces away from the starter when you connect it.
2. Install the automatic transmission fluid (ATF) dipstick.
3. Connect the 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 codes for the radio and the navigation system, then enter the customer's audio presets.
6. Do the power window control unit reset procedure (see «RESETTING THE POWER WINDOW CONTROL UNIT»(ref-243312-S03263640362006082300000) ).
7. Set the clock (on vehicles without navigation).

Scheme 12

Brush Holder Removal

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Scheme 18

Scheme 19

Scheme 20

Scheme 21

Scheme 22

Scheme 23

Scheme 24

Scheme 25

Scheme 26

Scheme 27

Scheme 28

1. Remove the starter (see «STARTER REMOVAL AND INSTALLATION»(ref-243307-S32823368072006082300000) ).
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. Armature Inspection and Test
5. Disassemble the starter (Scheme 12)at the beginning of this procedure.
6. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage, replace the armature.
7. 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).
8. Check the commutator diameter. If the diameter is out of 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.)
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.)
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): 0.40-0.50 mm (0.016-0.020 in.) Service Limit: 0.20 mm (0.008 in.)
11. Check for continuity between the segments of the commutator. If there is an open circuit between any segments, replace the armature.
12. Place the armature (A) on an armature tester (B). Hold a hacksaw blade (C) on the armature core. If the blade is attached to the core or vibrates while the core is turned, the armature is shorted. Replace the armature.
13. Use an ohmmeter to check for continuity betweeen 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
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.) Starter Brush Holder Test
15. Check for continuity between the (+) brush (A) and (-) brush (B). If there is continuity, replace the brush holder assembly. Planetary Gear Inspection
16. Check the planetary gears (A) and ring gear (B). Replace them if they are worn or damaged. Overrunning Clutch Inspection
17. Slide the overrunning clutch along the shaft. Replace it if it does not slide smoothly.
18. Rotate the overrunning clutch (A) in both directions. It should lock and move upward in one direction and rotate smoothly in the other direction. If it does not lock in either direction or if it locks both directions, then replace it.
19. If the starter drive gear (B) is worn or damaged, replace the overrunning clutch assembly; the gear is not available separately. Check the condition of the idler gear and drive plate ring gear to see if the starter drive gear teeth are damaged. Starter Reassembly
20. Install the armature into the housing.
21. Place the brush holder assembly on the armature, then move the brush holder (A) down to the armature.
22. Install the end cover to retain the brush holder.