ENGINE

SECTION STR
STARTING SYSTEM
STR

E
CONTENTS
BASIC INSPECTION .................................... 2 STARTING SYSTEM ......................................... 18 F
Symptom Table .......................................................18
DIAGNOSIS AND REPAIR WORKFLOW .......... 2
PRECAUTION .............................................. 19 G
K9K MODELS .............................................................. 2
K9K MODELS : Work Flow ....................................... 2 PRECAUTIONS ................................................. 19
Supplemental Restraint System (SRS) "AIR BAG"
HR16DE/MR20DE MODELS ....................................... 4 H
and "SEAT BELT PRE-TENSIONER" .....................19
HR16DE/MR20DE MODELS : Work Flow ................ 4
ON-VEHICLE REPAIR ................................. 20
FUNCTION DIAGNOSIS ............................... 8
STARTER MOTOR ........................................... 20 I
STARTING SYSTEM ........................................... 8
System Diagram ........................................................ 8 K9K MODELS ............................................................20
System Description ................................................... 8 K9K MODELS : Exploded View ...............................20 J
Component Parts Location ........................................ 8 K9K MODELS : Removal and Installation ...............20
Component Description ............................................ 9
HR16DE MODELS .....................................................20
COMPONENT DIAGNOSIS ......................... 10 HR16DE MODELS : Exploded View .......................20 K
HR16DE MODELS : Removal and Installation ........22
B TERMINAL CIRCUIT ......................................10 HR16DE MODELS : Disassembly and Assembly....22
Description .............................................................. 10 HR16DE MODELS : Inspection ...............................22 L
Diagnosis Procedure ............................................... 10
MR20DE MODELS .....................................................25
S TERMINAL CIRCUIT ......................................11 MR20DE MODELS : Exploded View .......................25
Description .............................................................. 11 MR20DE MODELS : Removal and Installation .......27 M
Diagnosis Procedure ............................................... 11 MR20DE MODELS : Disassembly and Assembly....27
MR20DE MODELS : Inspection ..............................27
STARTING SYSTEM ..........................................12
N
Wiring Diagram - STARTING SYSTEM (M/T SERVICE DATA AND SPECIFICATIONS
MODELS) - .............................................................. 12 (SDS) ............................................................ 31
Wiring Diagram - STARTING SYSTEM (CVT
MODELS) - .............................................................. 15 SERVICE DATA AND SPECIFICATIONS O
(SDS) ................................................................. 31
SYMPTOM DIAGNOSIS .............................. 18 Starter Motor ...........................................................31
P

STR-1
 DIAGNOSIS AND REPAIR WORKFLOW
< BASIC INSPECTION >
BASIC INSPECTION
DIAGNOSIS AND REPAIR WORKFLOW
K9K MODELS
K9K MODELS : Work Flow INFOID:0000000001116764

OVERALL SEQUENCE

JSBIA0008GB

STR-2
 DIAGNOSIS AND REPAIR WORKFLOW
< BASIC INSPECTION >
DETAILED FLOW
NOTE: A
If any malfunction is found, immediately disconnect the battery cable from the negative terminal.
[Link] ENGINE START
STR
Crank the engine and check that the engine starts.
Does the engine start?
YES >> GO TO 2. C
NO >> GO TO 3.
[Link] THAT THE STARTER MOTOR STOPS
Check that the starter motor stops after starting the engine. D
Does the starter motor stop?
YES >> INSPECTION END
NO >> Replace starter motor. E

[Link] THE ENGINE SPEED WITH CRANKING

Check that the engine runs at cranking. F
Does engine turn by cranking?
YES >> GO TO 4.
NO >> GO TO 5. G
[Link] THE ENGINE SPEED WITH CRANKING
Check that the engine speed is not low at cranking.
H
Does engine turn normally?
YES >> Check ignition/fuel system.
NO >> Check charge condition, corrosion and connection condition of the battery. Refer to PG-4, "Work
I
Flow".
[Link] STARTER MOTOR ACTIVATION
Check that the starter motor runs at cranking. J
Does starter motor turn?
YES >> GO TO 6.
NO >> GO TO 7. K
[Link] ROTATION STATUS
Check that the engine can be rotated by hand. L
Does engine turn freely by hand?
YES >> Replace starter motor.
NO >> Perform further diagnosis of engine mechanical or powertrain mechanism. Refer to EM, TM or CL M
sections.
[Link] POWER SUPPLY CIRCUIT
Check the following conditions. N
• Fuse and fusible link
• Charge condition, corrosion and connection condition of the battery. Refer to PG-4, "Work Flow".
Are these inspection results normal? O
YES >> GO TO 8.
NO >> Repair as needed.
[Link] STARTING SYSTEM WIRING P

Check the following.

• “B” terminal circuit. Refer to STR-10, "Diagnosis Procedure"
• “S” terminal circuit. Refer to STR-11, "Diagnosis Procedure"
Are these inspection results normal?
YES >> GO TO 9.
NO >> Repair as needed.

STR-3
 DIAGNOSIS AND REPAIR WORKFLOW
< BASIC INSPECTION >
[Link] MAGNETIC SWITCH OPERATION SOUND
Check that a magnetic switch operation sound can be heard when the ignition switch is set at the starting posi-
tion.
Does magnetic switch operation sound occur?
YES >> GO TO 10.
NO >> Replace starter motor.
[Link] AND RING GEAR ENGAGEMENT CHECK
Check condition of pinion and ring gear mesh.
Is the inspection result normal?
YES >> Replace starter motor.
NO >> GO TO 11.
[Link] STARTER MOTOR UNIT
Check the following.
• Check pinion moving mechanism.
• Check ring gear.
Are these inspection results normal?
YES >> INSPECTION END
NO >> Repair or replace, if necessary.

HR16DE/MR20DE MODELS
HR16DE/MR20DE MODELS : Work Flow INFOID:0000000000955263

STR-4
 DIAGNOSIS AND REPAIR WORKFLOW
< BASIC INSPECTION >
OVERALL SEQUENCE
A

STR

JPBIA0502GB
P
DETAILED FLOW
NOTE:
If any malfunction is found, immediately disconnect the battery cable from the negative terminal.
[Link] ENGINE START
Crank the engine and check that the engine starts.
Does the engine start?

STR-5
 DIAGNOSIS AND REPAIR WORKFLOW
< BASIC INSPECTION >
YES >> GO TO 2.
NO >> GO TO 3.
[Link] THAT THE STARTER MOTOR STOPS
Check that the starter motor stops after starting the engine.
Does the starter motor stop?
YES >> INSPECTION END
NO >> Replace magnetic switch.
[Link] THE ENGINE SPEED WITH CRANKING
Check that the engine runs at cranking.
Does engine turn by cranking?
YES >> GO TO 4.
NO >> GO TO 5.
[Link] THE ENGINE SPEED WITH CRANKING
Check that the engine speed is not low at cranking.
Does engine turn normally?
YES >> Check ignition/fuel system.
NO >> Check charge condition, corrosion and connection condition of the battery. Refer to PG-4, "Work
Flow".
[Link] STARTER MOTOR ACTIVATION
Check that the starter motor runs at cranking.
Does starter motor turn?
YES >> GO TO 6.
NO >> GO TO 7.
[Link] STARTER MOTOR UNIT
1. Remove starter motor.
2. Check that the gear shaft of starter motor rotates.
Does gear shaft turn?
YES >> • Check pinion clutch. Refer to the following.
- HR16DE models: STR-22, "HR16DE MODELS : Inspection".
- MR20DE models: STR-27, "MR20DE MODELS : Inspection".
NO >> Check reduction gear, armature and gear shaft.
[Link] POWER SUPPLY CIRCUIT
Check the following conditions.
• Fuse and fusible link
• Charge condition, corrosion and connection condition of the battery. Refer to PG-4, "Work Flow".
Are these inspection results normal?
YES >> GO TO 8.
NO >> Repair as needed.
[Link] STARTING SYSTEM WIRING
Check the following.
• “B” terminal circuit. Refer to STR-10, "Diagnosis Procedure"
• “S” terminal circuit. Refer to STR-11, "Diagnosis Procedure"
Are these inspection results normal?
YES >> GO TO 9.
NO >> Repair as needed.
[Link] MAGNETIC SWITCH OPERATION SOUND
Check that a magnetic switch operation sound can be heard when the ignition switch is set at the starting posi-
tion.
Does magnetic switch operation sound occur?

STR-6
 DIAGNOSIS AND REPAIR WORKFLOW
< BASIC INSPECTION >
YES >> GO TO 10.
NO >> Replace magnetic switch. A
[Link] AND RING GEAR ENGAGEMENT CHECK
Check condition of pinion and ring gear mesh.
STR
Is the inspection result normal?
YES >> GO TO 12.
NO >> GO TO 11.
C
[Link] STARTER MOTOR UNIT
Check the following.
• Adjust pinion movement. Refer to the following. D
- HR16DE models: STR-22, "HR16DE MODELS : Inspection"
- MR20DE engine models: STR-27, "MR20DE MODELS : Inspection"
• Check pinion moving mechanism. E
• Check ring gear.
Are these inspection results normal?
YES >> INSPECTION END F
NO >> Repair or replace, if necessary.
[Link] STARTER MOTOR UNIT
Check that the starter motor runs when connecting the positive ter- G
minal (12 V) to starter motor terminal M and the negative terminal
(ground) to starter motor body.
Does the starter motor run? H
YES >> Replace magnetic switch.
NO >> Repair starter motor.
I

SEL009Z
J

STR-7
 STARTING SYSTEM
< FUNCTION DIAGNOSIS >
FUNCTION DIAGNOSIS
STARTING SYSTEM
System Diagram INFOID:0000000000955264

JPBIA0547GB

System Description INFOID:0000000000955265

The starter motor plunger closes and provides a closed circuit between the battery and starter motor. The
starter motor is grounded to the engine block. With power and ground supplied, cranking occurs and the
engine starts.
Component Parts Location INFOID:0000000000955266

STR-8
 STARTING SYSTEM
< FUNCTION DIAGNOSIS >

STR

E
JPBIA0546ZZ

1. Starter motor 2. Battery 3. IPDM E/R

F
4. Park/neutral position switch
(CVT models only)
A. Engine B. Engine room (left side) C. CVT assembly
G

Component Description INFOID:0000000000955267

H

Component part Description

Park/neutral position switch supplies power to the starter relay in- I
Park/neutral position switch (CVT models only) side IPDM E/R when the selector lever is shifted to the P or N po-
sition.
CPU inside IPDM E/R controls the starter relay. Ignition relay in- J
IPDM E/R side IPDM E/R supplies power to the Park/neutral position switch
when ignition switch is ON or START.
The starter motor plunger closes and the motor is supplied with
Starter motor battery power, which in turn cranks the engine, when the “S” ter-
K
minal is supplied with electric power.

STR-9
 B TERMINAL CIRCUIT
< COMPONENT DIAGNOSIS >
COMPONENT DIAGNOSIS
B TERMINAL CIRCUIT
Description INFOID:0000000000955268

The “B” terminal is constantly supplied with battery power.

Diagnosis Procedure INFOID:0000000000955269

CAUTION:
Perform diagnosis under the condition that engine cannot start by the following procedure.
1. Remove fuel pump fuse.
2. Crank or start the engine (where possible) until the fuel pressure is released.
[Link] “B” TERMINAL CIRCUIT
1. Turn ignition switch OFF.
2. Check that starter motor “B” terminal connection is clean and tight.
3. Check voltage between starter motor “B” terminal and ground.

Terminals
(+) Voltage (Approx.)
(–)
Starter motor “B” terminal Terminal
F49 (K9K)
F52 (HR16DE) 2 Ground Battery voltage
F10 (MR20DE)
Is the inspection result normal?
YES >> GO TO 2.
NO >> Check harness between battery and starter motor for open circuit.
[Link] BATTERY CABLE CONNECTION STATUS (VOLTAGE DROP TEST)
1. Shift CVT selector lever to “P” or “N” position. (CVT models)
2. Check voltage between battery positive terminal and starter motor “B” terminal.

Terminals
(–)
Condition Voltage (Approx.)
(+) Starter motor
Terminal
“B” terminal
F49 (K9K)
When the ignition switch is Less than
Battery positive terminal F52 (HR16DE) 2
in START position 0.5 V
F10 (MR20DE)
Is the inspection result normal?
YES >> GO TO 3.
NO >> Check harness between the battery and the starter motor for poor continuity.
[Link] GROUND CIRCUIT STATUS (VOLTAGE DROP TEST)
1. Shift CVT selector lever to “P” or “N” position. (CVT models)
2. Check voltage between starter motor case and battery negative terminal.

Terminals
Condition Voltage (Approx.)
(+) (–)
When the ignition switch is in
Starter motor case Battery negative terminal Less than 0.2 V
START position
Is the inspection result normal?
YES >> “B” terminal circuit is OK. Further inspection is necessary. Refer to STR-4, "HR16DE/MR20DE
MODELS : Work Flow".
NO >> Check the starter motor case and ground for poor continuity.
STR-10
 S TERMINAL CIRCUIT
< COMPONENT DIAGNOSIS >
S TERMINAL CIRCUIT
A
Description INFOID:0000000000955270

The starter motor magnetic switch is supplied with power when the ignition switch is turned to START with the STR
selector lever P or N for CVT models.
Diagnosis Procedure INFOID:0000000000955271

C
CAUTION:
Perform diagnosis under the condition that engine cannot start by the following procedure.
1. Remove fuel pump fuse.
2. Crank or start the engine (where possible) until the fuel pressure is released. D

[Link] “S” CONNECTOR CIRCUIT

1. Turn ignition switch OFF. E
2. Disconnect “S” terminal.
3. Shift CVT selector lever to “P” or “N” position. (CVT models)
4. Check voltage between starter motor harness connector and ground.
F
Terminals
(+)
Condition Voltage (Approx.) G
Starter motor har- (–)
Terminal
ness connector
F50 (K9K) H
When the ignition switch is in
F53 (HR16DE) 1 Ground Battery voltage
START position
F11 (MR20DE)
Is the inspection result normal?
I
YES >> “S” terminal circuit is OK. Further inspection is necessary. Refer to STR-2, "K9K MODELS : Work
Flow" (K9K models) or STR-4, "HR16DE/MR20DE MODELS : Work Flow" (HR16DE/MR20DE
models).
NO >> GO TO 2. J

[Link] CONNECTOR
1. Turn ignition switch OFF. K
2. Check the following terminals and connectors for damage, bend and loose connection.
- Harness connector E8 (M/T models)
- Harness connector F122 (M/T models)
- Harness connector E6 (CVT models) L
- Harness connector F123 (CVT models)
Is the inspection result normal?
M
YES >> GO TO 3.
NO >> Repair the terminal and connector.
[Link] HARNESS CONTINUITY (OPEN CIRCUIT) N
1. Disconnect IPDM E/R connector.
2. Check continuity between starter motor “S” terminal and IPDM E/R harness connector.
O
Starter motor “S” terminal IPDM E/R harness connector
Continuity
Connector No. Terminal No. Connector No. Terminal No.
F50 (K9K) P
F53 (HR16DE) 1 E14 50 Existed
F11 (MR20DE)
Is the inspection result normal?
YES >> Inspect IPDM E/R and power supply circuit. Refer to SEC-5, "Work Flow".
NO >> Repair the harness.

STR-11
 STARTING SYSTEM
< COMPONENT DIAGNOSIS >
STARTING SYSTEM
Wiring Diagram - STARTING SYSTEM (M/T MODELS) - INFOID:0000000001059516

JCBWA0212GB

STR-12
 STARTING SYSTEM
< COMPONENT DIAGNOSIS >

STR

JCBWA0213GB

STR-13
 STARTING SYSTEM
< COMPONENT DIAGNOSIS >

JCBWA0214GB

STR-14
 STARTING SYSTEM
< COMPONENT DIAGNOSIS >
Wiring Diagram - STARTING SYSTEM (CVT MODELS) - INFOID:0000000001125396

STR

JCBWA0215GB

STR-15
 STARTING SYSTEM
< COMPONENT DIAGNOSIS >

JCBWA0216GB

STR-16
 STARTING SYSTEM
< COMPONENT DIAGNOSIS >

STR

JCBWA0217GB

STR-17
 STARTING SYSTEM
< SYMPTOM DIAGNOSIS >
SYMPTOM DIAGNOSIS
STARTING SYSTEM
Symptom Table INFOID:0000000000955272

Symptom Reference
No normal cranking Refer to STR-2, "K9K MODELS : Work Flow" (K9K models) or
STR-4, "HR16DE/MR20DE MODELS : Work Flow" (HR16DE/
Starter motor does not rotate MR20DE models).

STR-18
 PRECAUTIONS
< PRECAUTION >
PRECAUTION A
PRECAUTIONS
Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSION- STR
ER" INFOID:0000000000955273

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along C
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. D
Information necessary to service the system safely is included in the SRS and SB section of this Service Man-
ual.
WARNING: E
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision that would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer.
F
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the SRS section.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this G
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
H

STR-19
 STARTER MOTOR
< ON-VEHICLE REPAIR >
ON-VEHICLE REPAIR
STARTER MOTOR
K9K MODELS
K9K MODELS : Exploded View INFOID:0000000000955275

REMOVAL

JPBIA0519GB

1. “S” terminal nut 2. “B” terminal nut 3. Starter motor

4. Starter motor mounting bolt
: Engine front
Refer to GI-4, "Components" for symbols in the figure.

K9K MODELS : Removal and Installation INFOID:0000000000955276

REMOVAL
1. Disconnect the battery cable from the negative terminal.
2. Remove “S” terminal nut and “S” terminal harness.
3. Remove “B” terminal nut and “B” terminal harness.
4. Remove starter motor mounting bolts.
5. Remove starter motor upward from the vehicle.
INSTALLATION
Install in the reverse order of removal.
CAUTION:
Be sure to tighten “B” terminal nut carefully.
HR16DE MODELS
HR16DE MODELS : Exploded View INFOID:0000000000955718

REMOVAL

STR-20
 STARTER MOTOR
< ON-VEHICLE REPAIR >

STR

PKIC0987E F

1. Cylinder block 2. “B” terminal harness 3. “S” terminal harness

4. Starter motor
G
: Engine front
Refer to GI-4, "Components" for symbols in the figure.
H
DISASSEMBLY
Type: M000T32171
I

P
PKIC4906E

1. Magnetic switch assembly 2. Adjusting plate 3. Packing

4. Metal FR 5. Plate 6. Shift lever
7. Gear case 8. Yoke 9. Armature
10. Brush holder assembly 11. Metal RR 12. Rear cover

STR-21
 STARTER MOTOR
< ON-VEHICLE REPAIR >
13. Planetary gear 14. Gear shaft 15. Packing
16. Internal gear 17. Pinion assembly 18. Stopper
19. Stopper ring
(H): High-temperature grease point
Refer to GI-4, "Components" for symbols not described on the above.

HR16DE MODELS : Removal and Installation INFOID:0000000000955719

REMOVAL
1. Disconnect the battery cable from the negative terminal.
2. Remove “B” terminal nut and “B” terminal harness.
3. Remove “S” terminal nut and “S” terminal harness.
4. Remove starter motor mounting bolts.
5. Remove starter motor upward from the vehicle.
INSTALLATION
Install in the reverse order of removal.
CAUTION:
Be sure to tighten “B” terminal nut carefully.
HR16DE MODELS : Disassembly and Assembly INFOID:0000000000967656

ASSEMBLY
Apply high-temperature grease to lubricate the bearing, gears and frictional surface when assembling
the starter.
Carefully observe the following instructions.
Pinion Protrusion Length Adjustment

CLEARANCE
• With pinion driven out by magnetic switch, push pinion back to
remove slack and measure clearance “L” between the front edge
of the pinion and the pinion stopper.

Clearance “L” : Refer to SDS STR-31,

"Starter Motor".

SKIB0229E

• Adjust with the adjusting plate if the measurement value is not in

the specified area.

PKID0786E

HR16DE MODELS : Inspection INFOID:0000000000967657

INSPECTION
Magnetic Switch Check

STR-22
 STARTER MOTOR
< ON-VEHICLE REPAIR >
• Before starting to check, disconnect the battery cable from the negative terminal.
• Disconnect “M” terminal of starter motor. A
1. Continuity test [between “S” terminal (A) and switch body]

B : “B” terminal STR

C : “M” terminal

• Replace magnetic switch if continuity does not exist.

C

D
SKIB9002E

2. Continuity test [between “S” terminal (A) and “M” terminal (C)] E

B : “B” terminal

• Replace magnetic switch if continuity does not exist. F

SKIB9003E
H

Pinion/Clutch Check
1. Inspect pinion teeth. I
• Replace pinion if teeth are worn or damaged. (Also check con-
dition of ring gear teeth.)
2. Inspect reduction gear teeth (If equipped).
J
• Replace reduction gear if teeth are worn or damaged. (Also
check condition of armature shaft gear teeth.)
3. Check to see if pinion locks in one direction and rotates
smoothly in the opposite direction. K
• Replace pinion assembly if it is locked or rotated in both direc-
tions or unusual resistance is evident.
SEL630BA L
Brush Check

• Check wear of brush. M

Minimum length of brush : Refer to SDS STR-31,

"Starter Motor". N
• Replace brush if the measurement value is less than the specified
value.
O

SEL014Z
P
Brush Spring Check

STR-23
 STARTER MOTOR
< ON-VEHICLE REPAIR >
• Check brush spring tension with brush spring detached from
brush.

Spring tension (with new : Refer to SDS STR-31,

brush) "Starter Motor".
• Replace brush spring if the measurement value is less than the
specified value.

SEL015Z

Brush Holder Check

1. Perform insulation test between brush holder (positive side) and
its base (negative side).
• Replace brush holder assembly if continuity does not exist.
2. Check brush to see if it moves smoothly.
• If brush holder is bent, replace it; if sliding surface is dirty,
clean.

SKIB0460E

Yoke Check
Magnet is secured to yoke by bonding agent. Check magnet to see
that it is secured to yoke and for any cracks. Replace malfunctioning
parts as an assembly.
CAUTION:
Never clamp yoke in a vise or strike it with a hammer.

SEL305H

Armature Check
1. Continuity test (between two segments side by side)
• Replace armature assembly if continuity does not exist.
2. Insulation test (between each commutator bar and shaft)
• Replace armature assembly if continuity exists.

SKIB0461E

STR-24
 STARTER MOTOR
< ON-VEHICLE REPAIR >
3. Check commutator surface.
• Grind with No. 500 - 600 emery paper if it has a rough surface. A

STR

SEL020Z

D
4. Check diameter of commutator.

Commutator minimum di- : Refer to SDS STR-31, E

ameter "Starter Motor".
• Replace armature assembly if the measurement value is less
than the specified value. F

G
SEL021Z

5. Check depth of insulating mold from commutator surface. H

• Undercut to 0.5 to 0.8 mm (0.020 to 0.031 in) if the depth is 0.2
mm (0.008 in) or less.
I

SEL022Z

MR20DE MODELS O

MR20DE MODELS : Exploded View INFOID:0000000000955722

P
REMOVAL

STR-25
 STARTER MOTOR
< ON-VEHICLE REPAIR >

PKIC8095E

1. “S” terminal harness 2. “B” terminal harness 3. Starter motor

4. Cylinder block
: Engine front
Refer to GI-4, "Components" for symbols in the figure.

DISASSEMBLY
Type: S114-902A

JPBIA0549GB

1. Magnetic switch assembly 2. Dust cover kit 3. Shift lever set

4. Center bracket (A) 5. Yoke assembly 6. Armature assembly
7. Brush holder assembly 8. Thrust washer 9. Rear cover assembly
10. Internal gear 11. Planetary gear 12. Pinion shaft

STR-26
 STARTER MOTOR
< ON-VEHICLE REPAIR >
13. Packing 14. Thrust washer 15. Center bracket (P)
16. E-ring 17. Pinion assembly 18. Pinion stopper A
19. Pinion stopper clip 20. Gear case assembly
: High-temperature grease point
STR
Refer to GI-4, "Components" for symbols not described on the above.

MR20DE MODELS : Removal and Installation INFOID:0000000000955723

C
REMOVAL
1. Disconnect the battery cable from the negative terminal.
D
2. Disconnect the oil pressure switch connector.
3. Remove “B” terminal nut and “B” terminal harness.
4. Remove “S” terminal nut and “S” terminal harness. E
5. Remove starter motor mounting bolts.
6. Remove starter motor upward from the vehicle.
CAUTION: F
Never damage oil pressure switch when removing starter motor.
INSTALLATION
Install in the reverse order of removal. G
CAUTION:
Be sure to tighten “B” terminal nut carefully.
MR20DE MODELS : Disassembly and Assembly INFOID:0000000000955724
H

ASSEMBLY
Apply high-temperature grease to lubricate the bearing, gears and frictional surface when assembling I
the starter.
Carefully observe the following instructions.
Pinion Protrusion Length Adjustment J

CLEARANCE
• With pinion driven out by magnetic switch, push pinion back to K
remove slack and measure clearance “L” between the front edge
of the pinion and the pinion stopper.

Clearance “L” : Refer to SDS STR-31, L

"Starter Motor".

SKIB0229E
N

• Adjust with the adjusting plate if the measurement value is not in

the specified area.
O

PKID0786E

MR20DE MODELS : Inspection INFOID:0000000000955725

STR-27
 STARTER MOTOR
< ON-VEHICLE REPAIR >
INSPECTION
Magnetic Switch Check
• Before starting to check, disconnect the battery cable from the negative terminal.
• Disconnect “M” terminal of starter motor.
1. Continuity test [between “S” terminal (A) and switch body]

B : “B” terminal
C : “M” terminal

• Replace magnetic switch if continuity does not exist.

SKIB9002E

2. Continuity test [between “S” terminal (A) and “M” terminal (C)]

B : “B” terminal

• Replace magnetic switch if continuity does not exist.

SKIB9003E

Pinion/Clutch Check
1. Inspect pinion teeth.
• Replace pinion if teeth are worn or damaged. (Also check con-
dition of ring gear teeth.)
2. Inspect reduction gear teeth (If equipped).
• Replace reduction gear if teeth are worn or damaged. (Also
check condition of armature shaft gear teeth.)
3. Check to see if pinion locks in one direction and rotates
smoothly in the opposite direction.
• Replace pinion assembly if it is locked or rotated in both direc-
tions or unusual resistance is evident.
SEL630BA

Brush Check

• Check wear of brush.

Minimum length of brush : Refer to SDS STR-31,

"Starter Motor".
• Replace brush if the measurement value is less than the specified
value.

SEL014Z

Brush Spring Check

STR-28
 STARTER MOTOR
< ON-VEHICLE REPAIR >
• Check brush spring tension with brush spring detached from
brush. A

Spring tension (with new : Refer to SDS STR-31,

brush) "Starter Motor". STR
• Replace brush spring if the measurement value is less than the
specified value.
C

SEL015Z

D
Brush Holder Check
1. Perform insulation test between brush holder (positive side) and
its base (negative side).
• Replace brush holder assembly if continuity does not exist. E
2. Check brush to see if it moves smoothly.
• If brush holder is bent, replace it; if sliding surface is dirty,
clean. F

SKIB0460E

Yoke Check H
Magnet is secured to yoke by bonding agent. Check magnet to see
that it is secured to yoke and for any cracks. Replace malfunctioning
parts as an assembly.
I
CAUTION:
Never clamp yoke in a vise or strike it with a hammer.

K
SEL305H

Armature Check
L
1. Continuity test (between two segments side by side)
• Replace armature assembly if continuity does not exist.
2. Insulation test (between each commutator bar and shaft)
• Replace armature assembly if continuity exists. M

O
SKIB0461E

STR-29
 STARTER MOTOR
< ON-VEHICLE REPAIR >
3. Check commutator surface.
• Grind with No. 500 - 600 emery paper if it has a rough surface.

SEL020Z

4. Check diameter of commutator.

Commutator minimum di- : Refer to SDS STR-31,

ameter "Starter Motor".
• Replace armature assembly if the measurement value is less
than the specified value.

SEL021Z

5. Check depth of insulating mold from commutator surface.

• Undercut to 0.5 to 0.8 mm (0.020 to 0.031 in) if the depth is 0.2
mm (0.008 in) or less.

SEL022Z

STR-30
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS) A
SERVICE DATA AND SPECIFICATIONS (SDS)
Starter Motor INFOID:0000000000955279
STR

Applied model K9K HR16DE MR20DE

C
M000T87881 M000T32171 S114-902A
Type MITSUBISHI make MITSUBISHI make HITACHI make
Reduction gear type Reduction gear type Reduction gear type D
System voltage [V] — 12 12
Terminal voltage [V] — 11 11
E
No-load Current [A] — Less than 95 Less than 110
Revolution [rpm] — More than 3,000 More than 3,000
Minimum diameter of commutator [mm (in)] — 28.8 (1.134) 28.0 (1.102) F
Minimum length of brush [mm (in)] — 5.5 (0.217) 10.5 (0.413)
Brush spring tension [N (kg, lb)] — 17.7 (1.81, 3.98) 16.2 (1.65, 3.64)
Clearance between bearing metal and ar- G
[mm (in)] — Less than 0.2 (0.008) Less than 0.2 (0.008)
mature shaft
Clearance “L” between pinion front edge
[mm (in)] — 0.3 - 2.0 (0.012 - 0.079) 0.3 - 2.5 (0.012 - 0.098)
and pinion stopper H

STR-31