Starting System — Suzuki Grand Vitara II рестайлинг (2008-2012)

Cranking Circuit

The cranking circuit consists of the battery, starting motor, ignition switch, and related electrical wiring.

Starting Motor Circuit

In the circuit shown in CRANKING SYSTEM CIRCUIT DIAGRAM , the coil of the magnetic switch in starting motor is energized when the ignition switch is closed. The resulting movement of the plunger and pinion drive lever movement causes the pinion to engage the engine flywheel gear and the contact of the magnetic switch close, and cranking takes place.

When the engine starts, the pinion over-running clutch protects the armature from excessive speed until the switch is opened, at which time the return spring causes the pinion to disengage.

Scheme 1

Scheme 1: Cranking System Circuit Diagram

Cranking System Symptom Diagnosis

Possible symptoms of starting system trouble would be as follows

Starting motor does not run (or runs slowly).
Starting motor runs but fails to crank engine.
Abnormal noise is heard.

Proper diagnosis must be made to determine exactly where the cause of each trouble lies in battery, wiring harness, starting motor (including magnetic switch) or engine.

Do not remove starting motor just because starting motor does not run. Check the following items and narrow down scope of possible causes.

Condition of trouble
Tightness of battery terminals (including ground cable connection on engine) and starting motor terminals
Discharge of battery
Mounting of starting motor

Condition	Possible Cause	Action
Starting motor not running (No operating sound of magnetic switch)	Malfunction of Shift switch (4 A/T model and 5 A/T model)	Check shift switch . 4 A/T model: See TRANSMISSION RANGE SENSOR INSPECTION AND ADJUSTMENT 5 A/T model: See TRANSMISSION RANGE SENSOR INSPECTION AND ADJUSTMENT
	Malfunction of clutch switch (5 M/T model)	Check clutch switch . See CLUTCH PEDAL POSITION (CPP) SWITCH (FOR 4WD CONTROL MODULE) INSPECTION AND ADJUSTMENT
	Battery voltage is too low	Check battery . See BATTERY INSPECTION .
	Charging faulty due to deteriorated battery	Replace battery . See BATTERY REMOVAL AND INSTALLATION .
	Poor battery terminal connection	Check terminal connection or replace battery . See BATTERY REMOVAL AND INSTALLATION
	Poor ground cable connection	Tighten ground cable .
	Fuse blown	Replace fuse .
	Ignition switch faulty	Check ignition switch , see IGNITION SWITCH INSPECTION .
	Magnetic switch faulty	Check magnetic switch , see STARTING MOTOR INSPECTION .
	Poor magnetic switch lead wire connector connection	Check connector connection .
	Open-circuit between ignition switch and magnetic switch	Repair circuit .
	Open-circuit in pull-in coil	Check pull-in coil circuit . See STARTING MOTOR INSPECTION .
	Brushes and/or brush springs faulty	Check brushes and brush springs . See STARTING MOTOR INSPECTION .
	Poor sliding of plunger and/or pinion	Check plunger and pinion . See STARTING MOTOR INSPECTION .
	Starting motor control relay faulty	Check starting motor control relay . See STARTING MOTOR CONTROL RELAY INSPECTION .
	ECM and its circuit faulty	Check ECM and its circuit . N32A: See INSPECTION OF ECM AND ITS CIRCUITS . J24B: See INSPECTION OF ECM AND ITS CIRCUITS .
Starting motor not running (Operating sound of magnetic switch heard)	Battery voltage is too low	Check battery . See BATTERY INSPECTION .
	Charging faulty due to deteriorated battery	Replace battery . See BATTERY REMOVAL AND INSTALLATION .
	Poor battery terminal connection	Check terminal connection or replace battery . See BATTERY REMOVAL AND INSTALLATION .
	Poor ground terminal connection	Tighten ground cable .
	Magnetic switch faulty	Check magnetic switch . See STARTING MOTOR INSPECTION .
	Brushes and/or brush springs faulty	Check brushes and brush springs . See STARTING MOTOR INSPECTION .
	Brush holder faulty	Check brush holder . See STARTING MOTOR INSPECTION .
	Commutator burnt	Check commutator . See STARTING MOTOR INSPECTION .
	Short-circuit between commutator and armature	Check commutator . See STARTING MOTOR INSPECTION .
	Ignition switch faulty	Check ignition switch . See IGNITION SWITCH INSPECTION .
	Poor starting motor cable connection	Check starting motor cable connection . See STARTING MOTOR REMOVAL AND INSTALLATION .
	Open circuit between Ignition switch and magnetic switch	Repair circuit .
	Open circuit in pull-in coil	Check pull-in coil circuit . See STARTING MOTOR INSPECTION .
	Crank shaft rotation obstructed	Repair engine assembly .
Starting motor running but too slowly (small torque) (If battery and wiring are satisfactory, inspect starting motor)	Magnetic switch faulty	Check magnetic switch . See STARTING MOTOR INSPECTION .
	Short-circuit between commutator and armature	Check commutator . See STARTING MOTOR INSPECTION .
	Commutator burnt	Check commutator . See STARTING MOTOR INSPECTION .
	Brushes and/or brush springs faulty	Check brushes and brush springs . See STARTING MOTOR INSPECTION .
	Brush holder faulty	Check brush holder . See STARTING MOTOR INSPECTION .
	Rear bracket bush faulty	Check rear bracket bush . See STARTING MOTOR INSPECTION .
Starting motor running, but not cranking engine	Worn pinion tip	Replace over-running clutch . See STARTING MOTOR COMPONENTS .
	Poor sliding of over-running clutch	Check over-running clutch . See STARTING MOTOR INSPECTION .
	Over-running clutch slipping	Replace over-running clutch . See STARTING MOTOR COMPONENTS .
	Worn teeth of ring gear	Replace flywheel (M/T model) or drive plate (A/T model) . N32A: See DRIVE PLATE REMOVAL AND INSTALLATION . J24B: See FLYWHEEL/DRIVE PLATE REMOVAL AND INSTALLATION .
Noise	Abnormally worn bush	Replace bush . See STARTING MOTOR COMPONENTS .
	Worn teeth of pinion	Replace over-running clutch . See STARTING MOTOR COMPONENTS .
	Worn teeth of ring gear	Replace flywheel (M/T model) or drive plate (A/T model) . N32A: See DRIVE PLATE REMOVAL AND INSTALLATION . J24B: See FLYWHEEL/DRIVE PLATE REMOVAL AND INSTALLATION .

POSSIBLE CAUSE REFERENCE

Scheme 2

Scheme 2: Starting Motor Control Relay Inspection

Disconnect negative (-) cable from battery.
Remove starting motor control relay (1) from fuse box No. 2.
Check that there is no continuity between terminal "C" and "D". If there is continuity, replace starting motor control relay.
Connect service wire between battery positive (+) terminal and relay terminal "B". Connect service wire between battery negative (-) terminal and relay terminal "A". Check for continuity between terminal "C" and "D". If there is no continuity when relay is connected to the battery, replace starting motor control relay.

N32A

Note. For identification of each cylinder and bank, refer to PRECAUTION FOR IDENTIFICATION OF CYLINDER AND BANK: N32A .

Removal

Remove bank-2 exhaust manifold, see «EXHAUST MANIFOLD REMOVAL AND INSTALLATION (N32A)»(/suzuki/grand-vitara/ii-2008-2012/remont/exhaust/#engine-exhaust-system__exhaust-manifold-removal-and-installation-n32a) .
Remove knock sensor, see «KNOCK SENSOR REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/engine-control-systems/#engine-electrical-devices-n32a__knock-sensor-removal-and-installation) .
Disconnect magnetic switch lead wire (1) and starting motor cable (2) from starting motor.
Remove starting motor mounting bolts (3).
Remove starting motor (4).

Installation

Reference: STARTING MOTOR INSPECTION

Reverse removal procedure noting the following.

Tighten starting motor mounting bolts (3) and starting motor cable nut (5) to specified torques.

Tightening torque

Starting motor cable nut (a): 11 N.m (1.1 kg-m, 8.5 lbf-ft)

Starting motor mounting bolt (b): 45 N.m (4.6 kg-m, 33.5 lbf-ft)

Scheme 3

Disconnect negative (-) cable from battery.
Remove intake manifold, see «INTAKE MANIFOLD REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a__intake-manifold-removal-and-installation) .
Disconnect magnetic switch lead wire (1) and starting motor cable (2) from starting motor.
Remove starting motor mounting bolts (3).
Remove starting motor (4).

Reference: STARTING MOTOR INSPECTION

Reverse removal procedure noting the following.

Scheme 4

Scheme 4: Installation

Tighten starting motor mounting bolts (3) and starting motor cable nut (5) to specified torques. Tightening torque Starting motor cable nut (a): 11 N.m (1.1 kg-m, 8.5 lbf-ft) Starting motor mounting bolt (b): 45 N.m (4.6 kg-m, 33.5 lbf-ft)

Scheme 5

Scheme 5: Starting Motor Components

Starting Motor Inspection

Reference: STARTING MOTOR REMOVAL AND INSTALLATION

Reference: STARTING MOTOR COMPONENTS

Starting Motor Operation Check

CAUTION

When using battery, do not create short circuit between terminals together. Each test must be performed within 3 - 5 seconds to avoid burning of coil.

Scheme 6

Scheme 7

Scheme 8

Perform pull-in test as follows. Disconnect lead wire (3) from terminal "M" (2). Connect battery to magnetic switch as shown in figure. Check that plunger and pinion move outward. If plunger and pinion do not move, replace magnetic switch.
Perform hold-in test as follows. From the state of step 1 ) with plunger and pinion in "out" position, disconnect negative (-) lead from terminal "M". Check that plunger and pinion remain in "out" position. If plunger and pinion return inward, replace magnetic switch.
Perform plunger and pinion return test as follows. From the state of step 2 ) with plunger and pinion in "out" position, disconnect negative (-) lead from starting motor body. Check that plunger and pinion return inward. If plunger and pinion do not return, replace magnetic switch.
Perform no-load performance test as follows. CAUTION: Use thick cable such as jumper cable, as large current may flow. Connect battery and ammeter to starting motor as shown in figure. Check that starting motor rotates smoothly and steadily with pinion moving out. Check that ammeter indicates specified current. If check result is not satisfactory, repair or replace starting motor. Specified current (No-load performance test) 90 A MAX. at 11 V

Plunger

Check plunger for wear. Replace magnetic switch if necessary.

Scheme 9

Scheme 9: Plunger

Magnetic Switch

Push in plunger and release it. Plunger should return quickly to its original position. Replace magnetic switch if necessary.

Scheme 10

Scheme 10: Magnetic Switch

Pull-in coil open circuit test

Check for continuity between magnetic switch "S" terminal (1) and "M" terminal (2). If there is no continuity, coil is open and magnetic switch should be replaced.

Scheme 11

Scheme 11: Pull-in coil open circuit test

Hold-in coil open circuit test

Check for continuity between magnetic switch "S" terminal (1) and coil case. If there is no continuity, coil is open and magnetic switch should be replaced.

Scheme 12

Scheme 12: Hold-in coil open circuit test

End Housing Bush

Check end housing bush for wear or damage. Replace bush if necessary.

Scheme 13

Scheme 13: End Housing Bush

Scheme 14

Scheme 14: Brush

Check brushes for wear. Measure length of each brush and if measurement is below the limit, replace brush assembly. Brush length Standard: 12.3 mm (0.484 in.) Limit: 5.5 mm (0.22 in.)
Install brushes to their holders and check them for smooth movement.

Spring

Check brush springs for wear, damage or other abnormal conditions. Replace brush assembly if necessary.

Brush spring tension

Standard: 15 - 20 N.m (1.5 kgf - 2.0 kgf, 3.4 - 4.5 lbf)

Limit: 2.8 N (0.29 kgf, 0.63 lbf)

Scheme 15

Scheme 15: Brush Holder

Check movement of each brush in holder. If brush movement within brush holder is sluggish, check brush holder for distortion and sliding surfaces for contamination. Clean or correct brush holder as necessary.
Check for continuity across insulated brush (positive (+) side) and grounded brush (negative (-) side). If continuity exists, brush holder is grounded due to defective insulation and should be replaced.

Scheme 16

Scheme 16: Armature

Scheme 17

Scheme 18

Scheme 19

Scheme 20

Scheme 21

Check commutator for dirt or burn. Correct commutator with sandpaper or lathe, if necessary.
Check commutator for uneven wear with armature (1) supported on V-blocks (2). If dial gauge (4) deflects exceeding the limit, repair commutator or replace armature. Commutator out of round Standard: 0.05 mm (0.002 in.) or less Limit: 0.4 mm (0.02 in.)
Check commutator for wear. If diameter is below limit, replace armature. Commutator outside diameter Standard: 29.4 mm (1.16 in.) Limit: 28.8 mm (1.14 in.)
Check commutator (1) for insulator (2) depth. Correct insulator depth or replace commutator if measurement is below limit. Commutator insulator depth "a" Standard: 0.5 mm (0.020 in) Limit: 0.2 mm (0.008 in.)
Check insulation between commutator and armature core. If there is continuity, armature is grounded and must be replaced.
Check for continuity between segments. If there is no continuity at any test point, there is an open circuit and armature must be replaced.

Gears

Check internal gear and planetary gears for wear, damage or other abnormal conditions. Replace gear set if necessary.

Scheme 22

Scheme 22: Gears

Scheme 23

Scheme 23: Pinion and Overrunning Clutch

Scheme 24

Check pinion for wear, damage or other abnormal conditions.
Check that clutch locks up when turned in direction of drive and rotates smoothly in reverse direction. Replace pinion and overrunning clutch if necessary.
Check spline teeth for wear or damage. Replace pinion and overrunning clutch if necessary.
Check pinion for smooth movement.

Armature Housing Bush

Check bush for wear or damage. Replace bush if necessary.

Scheme 25

Scheme 25: Armature Housing Bush

Cranking System Specifications

Voltage		12 V
Output		1.4 kW
Rating		30 seconds
Direction of rotation		Clockwise as viewed from pinion side
Number of pinion teeth		N32A: 12 teeth, J24B: 8 teeth
Performance Voltage Current Torque		Revolution speed
Around at 20 °C (68 °F)	No-load characteristic	11.0 V	90 A MAX		2000 RPM MIN
	Loaded characteristic	7.5 V	300 A	11.0 N.m (1.1 kgf-m, 8.5 lbf-ft) minimum	840 RPM MIN
	Locked characteristic	3.0 V	860 A MAX	20.0 N.m (2.0 kgf-m, 15.0 lbf-ft) minimum
	Magnetic switch operating voltage	8 V or less

CRANKING SYSTEM SPECIFICATIONS

Tightening Torque Specifications