Disconnect the field coil lead from the terminal C. Connect the battery to the solenoid switch as shown. See if the clutch pinion gear movement is outward. If the gear does not move perform the hold-in test.
Attach the battery to the starter as shown and with the clutch pinion gear out, disconnect the negative lead from terminal C. Check to make sure the pinion gear stays in the outward position. If the clutch gear returns inwards, perform the clutch pinion gear return test.
Disconnect the negative lead from the solenoid body. Check the clutch pinion gear returns inward. If not perform the no-load test.
Attach a battery and ammeter to the starter. Check that the starter rotates smoothly and steadily with the pinion gear moving out. Check the ammeter shows the correct current. 90 amps or less at 11.5 volts on gasoline engines. If not replace the starter.
- Disconnect the cable from the negative terminal of the battery.
- On some early models with cruise control, you may have to remove the battery.
- Also on some models with cruise control, remove the actuator cover and disconnect the wiring harness. Remove the three bolts and then lift out the cruise control actuator. Remove the bracket from beneath the actuator and put aside.
- Peel the rubber boot away and remove the nut and disconnect the negative battery cable from the magnetic switch terminal on the starter. Disconnect the electrical connector also located on the magnetic switch.
- Support the starter by hand and remove the two mounting bolts.
- Remove the starter from the transaxle.
- Place the starter motor in the transaxle and support by hand.
- Install the two mounting bolts and tighten them to 29-31 ft. lbs. (39-42 Nm).
- Connect the connector to the magnetic switch. Place the battery cable on the switch terminal and install the nut. Tighten the nut and position the rubber boot over the cable.
- Using the ignition switch, "bump" the starter over a few times and check for proper operation.
The starter solenoid (magnetic switch) is an integral part of the starter assembly.
- Remove the starter from the car. Remove the heat insulator from the starter assembly, if equipped.
- Disconnect the wire lead from the magnetic switch terminal.
- Remove the two long, through bolts holding the field frame to the magnetic switch. Pull out the field frame with the armature from the magnetic switch.
- On 1.0 kW starters, remove the felt seal. On 1.4 kW starters, remove the O-ring.
- To remove the starter housing from the magnetic switch assembly:
- On 1.0 kW starters, remove the two screws and the starter housing with the idler gear and clutch assembly.
- On 1.4 kW units, remove the two screws and the starter housing with the pinion gear, idler and clutch assembly.
- If necessary, install the gears and clutch assembly to the starter housing. Apply grease to the gear and clutch assemblies and:
- On 1.0 kW starters, place the clutch assembly, idler gear and bearing in the starter housing.
- On 1.4 kW starters, place the clutch assembly, idler gear, bearing and pinion gear in the starter housing.
- Insert the spring into the clutch shaft hole and place the starter housing onto the magnetic switch. Install the two screws.
- On 1.0 kW units, install the felt seal on the armature shaft. On 1.4 kW units, install the O-ring on the field frame.
- Install the field frame with the armature onto the magnetic switch assembly and install the two through bolts.
- Connect the wire to the terminal on the magnetic switch. Install the heat insulator, if equipped.
- Reinstall the starter on the vehicle. Check starter system for proper operation.