Honda CIVIC 10G 2016 Starter Overhaul Page 1

Starter Overhaul
1
Replace
*1 Do not wipe off the special grease applied.
Starter Overhaul 2908 http://techinfo.honda.com/rjanisis/pubs/sm/1/2/Contents/enu/61TBAD/R...
1 of 11 1/19/2019 5:17 PM
cardiagn.com

Contents Summary of Starter Overhaul

  • Page 1Starter Overhaul 1 cardiagn.com Replace *1 Do not wipe off the special grease applied.
  • Page 2*2 These parts have inspection items. cardiagn.com
  • Page 31. End Cover - Remove 2. Armature Housing - Remove 3. Armature - Remove 4. Terminal - Remove 5. Brush Spring - Remove cardiagn.com 6. Moving Contact - Remove 7. Brush Holder Assembly - Remove 8. Planetary Gear Assembly - Remove 9. Switch Shaft - Remove 10.Switch Plunger - Remove 11. Gear Plunger - R
  • Page 41. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage, replace the armature. 2. Check the commutator (A) surface. If the surface is dirty or burnt, resurface it with an emery cloth or a lathe to the specifications in step 3, or recondition with
  • Page 54. 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): 0.02 mm (0.0008 in)
  • Page 66. Use an ohmmeter to check for continuity between the segments of the commutator. If there is an open circuit between any of the segments, replace the armature. 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
  • Page 71. Check for continuity between the (+) brushes (A) and the (-) brushes (B). If there is continuity, replace the brush holder assembly. 2. Measure the brush length. If it is shorter than the service limit, replace the brush holder assembly. Brush Length Standard (New): 11.1-11.5 mm (0.437-0.453 in)
  • Page 81. Check the planetary gears (A), the gear shaft (B), and the internal ring gear (C). Replace them if they are worn or damaged. Gear Cover Assembly cardiagn.com 1. Overrunning Clutch - Inspect 1. Hold the drive gear (A), turn the gear shaft (B) counterclockwise. Check that the drive gear comes out t
  • Page 9cardiagn.com Detailed information, notes, and precautions Torque: N·m (kgf·m, lbf·ft) Replace *1 Do not wipe off the special grease applied. *2 These parts have inspection items. 1. Gear Plunger - Install
  • Page 102. Switch Plunger - Install 3. Switch Shaft - Install 4. Planetary Gear Assembly - Install 5. Brush Holder Assembly - Install 6. Moving Contact - Install 7. Terminal - Install cardiagn.com 8. Armature - Install NOTE: To seat the new brushes, slip a strip of #500 or #600 sandpaper, with the grit side
  • Page 1111. End Cover - Install cardiagn.com
  • Page 12Starter Overhaul 1 cardiagn.com Replace *1 Do not wipe off the special grease applied.
  • Page 13*2 These parts have inspection items. cardiagn.com
  • Page 141. End Cover - Remove 2. Armature Housing - Remove 3. Armature - Remove 4. Terminal Cap - Remove 5. Terminal - Remove cardiagn.com 6. Switch Cover - Remove 7. Brush Spring - Remove 8. Push Nut - Remove 9. Contact Spring - Remove 10.Moving Contact - Remove 11. Brush Holder Assembly - Remove 12.Planet
  • Page 1515.Gear Plunger - Remove NOTE: Where icon is shown, click for further information. 1 cardiagn.com
  • Page 16cardiagn.com Detailed information, notes, and precautions Torque: N·m (kgf·m, lbf·ft) Replace *1 Do not wipe off the special grease applied. *2 These parts have inspection items. 1. Gear Plunger - Install
  • Page 172. Switch Plunger - Install 3. Switch Shaft - Install 4. Planetary Gear Assembly - Install 5. Brush Holder Assembly - Install 6. Moving Contact - Install 7. Contact Spring - Install cardiagn.com 8. Push Nut - Install 9. Switch Cover - Install 10.Terminal - Install 11. Terminal Cap - Install 12.Armat
  • Page 181. While squeezing a spring (A), insert it in the hole on the brush holder, and push it until it bottoms. Repeat this for the other three springs (B, C, and D). 14.Armature Housing - Install cardiagn.com 15.End Cover - Install Armature 1. Armature - Inspect 1. Inspect the armature for wear or damage
  • Page 192. Check the commutator (A) surface. If the surface is dirty or burnt, resurface it with an emery cloth or a lathe to the specifications in step 3, or recondition with #500 or #600 sandpaper (B). 3. Check the commutator diameter with a digital caliper or dial type caliper. If the diameter is below t
  • Page 205. Use a digital caliper or dial type caliper to check the mica depth (A). If the mica depth is below the service limit, replace the armature. Commutator Mica Depth Standard (New): 0.40-0.50 mm (0.0157-0.0197 in) cardiagn.com Service Limit: 0.15 mm (0.0059 in) 6. Use an ohmmeter to check for continu
  • Page 217. 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 while the core is turned, the armature is shorted. Replace the armature. 8. Use an ohmmeter to check for continuity between the commutator (A) and the armature co
  • Page 22Brush Length Standard (New): 11.1-11.5 mm (0.437-0.453 in) Service Limit: 4.3 mm (0.169 in) Planetary Gear Assembly 1. Planetary Gear - Inspect cardiagn.com 1. Check the planetary gears (A), the gear shaft (B), and the internal ring gear (C). Replace them if they are worn or damaged. Gear Cover Set
  • Page 231. Hold the drive gear (A), turn the gear shaft (B) counterclockwise. Check that the drive gear comes out to the other end. If the drive gear does not move smoothly, replace the gear cover set. 2. Hold the drive gear, turn the gear shaft clockwise. The gear shaft should turn freely. If the gear shaf
  • Page 24Starter Overhaul 1 cardiagn.com Replace *1 Do not wipe off the special grease applied.
  • Page 25*2 These parts have inspection items. cardiagn.com
  • Page 261. End Cover - Remove 2. Armature Housing - Remove 3. Armature - Remove 4. Terminal - Remove 5. Brush Spring - Remove cardiagn.com 6. Moving Contact - Remove 7. Brush Holder Assembly - Remove 8. Planetary Gear Assembly - Remove 9. Switch Shaft - Remove 10.Switch Plunger - Remove 11. Gear Plunger - R
  • Page 271. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage, replace the armature. 2. Check the commutator (A) surface. If the surface is dirty or burnt, resurface it with an emery cloth or a lathe to the specifications in step 3, or recondition with
  • Page 284. 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): 0.02 mm (0.0008 in)
  • Page 297. 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 while the core is turned, the armature is shorted. Replace the armature. 8. Use an ohmmeter to check for continuity between the commutator (A) and the armature co
  • Page 30Brush Length Standard (New): 11.1-11.5 mm (0.437-0.453 in) Service Limit: 4.3 mm (0.169 in) Planetary Gear Assembly 1. Planetary Gear - Inspect cardiagn.com 1. Check the planetary gears (A), the gear shaft (B), and the internal ring gear (C). Replace them if they are worn or damaged. Gear Cover Set
  • Page 311. Hold the drive gear (A), turn the gear shaft (B) counterclockwise. Check that the drive gear comes out to the other end. If the drive gear does not move smoothly, replace the gear cover set. 2. Hold the drive gear, turn the gear shaft clockwise. The gear shaft should turn freely. If the gear shaf
  • Page 32cardiagn.com Detailed information, notes, and precautions Torque: N·m (kgf·m, lbf·ft) Replace *1 Do not wipe off the special grease applied. *2 These parts have inspection items. 1. Gear Plunger - Install
  • Page 332. Switch Plunger - Install 3. Switch Shaft - Install 4. Planetary Gear Assembly - Install 5. Brush Holder Assembly - Install 6. Moving Contact - Install 7. Terminal - Install cardiagn.com 8. Armature - Install NOTE: To seat the new brushes, slip a strip of #500 or #600 sandpaper, with the grit side
  • Page 3411. End Cover - Install cardiagn.com
  • Page 35How to Run the Starter In order to prevent damage of the starter, crank the starter according to the cycle shown in the table below. cardiagn.com
  • Page 36How to Run the Starter In order to prevent damage of the starter, crank the starter according to the cycle shown in the table below. cardiagn.com
  • Page 37Starter Removal, Installation, and Performance Test NOTE: How to read the torque specifications. 1. 12 Volt Battery Terminal - Disconnect 2. Engine Undercover - Remove 3. Front Floor Brace - Remove (With Front Floor Brace) 4. Exhaust Pipe A - Remove cardiagn.com 5. Positive Starter Cable and Connect
  • Page 38cardiagn.com 7. All Removed Parts - Install 1. Install the parts in the reverse order of removal. NOTE: Make sure the crimped side of the ring terminal faces away from the starter when you connect the positive starter cable. 1. Starter Performance - Test 1. Clamp the starter firmly in a vise. 2. Mak
  • Page 394. Disconnect the 12 volt battery from the starter body, and check for continuity between the B terminal and the starter body. If there is no continuity, it is working properly. 5. Connect the starter to the 12 volt battery as shown, and confirm that the motor runs. 6. If the electric current meets
  • Page 40Starter Removal, Installation, and Performance Test NOTE: Where icon is shown, click for further information. 1 cardiagn.com Detailed information, notes, and precautions Torque: N·m (kgf·m, lbf·ft) 1. 12 Volt Battery Terminal - Disconnect
  • Page 41cardiagn.co
  • Page 422. Exhaust Pipe A - Remove 3. Positive Starter Cable - Disconnect Note for installation Make sure the crimped side of the ring terminal faces away from the starter when you connect the positive starter cable. 4. Starter - Remove 5. All Removed Parts - Install 1. Install the parts in the reverse orde
  • Page 435. Connect the starter to the 12 volt battery as shown, and confirm that the motor runs. 6. If the electric current meets the specification when the 12 volt battery voltage is at 11.5 V, the starter is working properly. Specification Electric Current: 80 A or less cardiagn.com
  • Page 44Starter Removal, Installation, and Performance Test 1. 12 Volt Battery Terminal - Disconnect 2. Engine Undercover - Remove 3. Exhaust Pipe A - Remove 4. Positive Starter Cable and Connector (S Terminal) - Disconnect 1. Remove the harness clamp (A). cardiagn.com 2. Disconnect the positive starter cab
  • Page 45cardiagn.com 6. All Removed Parts - Install 1. Install the parts in the reverse order of removal. NOTE: Make sure the crimped side of the ring terminal faces away from the starter when you connect the positive starter cable. 1. Starter Performance - Test 1. Clamp the starter firmly in a vise. 2. Mak
  • Page 464. Disconnect the 12 volt battery from the starter body, and check for continuity between the B terminal and the starter body. If there is no continuity, it is working properly. 5. Connect the starter to the 12 volt battery as shown, and confirm that the motor runs. 6. If the electric current meets
  • Page 47Starter System Circuit Troubleshooting cardiagn.com Starter System Circuit Troubleshooting
  • Page 48NOTE: cardiagn.com
  • Page 49Air temperature must be between 59-100 °F (15-38 °C) during this procedure. After the inspection, you must reset the PCM. Otherwise, the PCM will continue to stop the fuel injectors from operating. The 12 volt battery must be in good condition and fully charged. 1. PGM-FI, CVT, and Keyless Access sy
  • Page 50Starter cranks normally Repairing the loose connection corrected the problem. Do the PCM reset in the PGM-FI mode menu to cancel All INJECTORS STOP with the HDS.■ Starter does not crank engine at all If the starter does not crank the engine at all, go to step 4. Starter cranks abnormally If the star
  • Page 51YES (without keyless access system) Check the following items in the order listed until you find the problem in the circuit:■ Check the ignition switch. Check the relay circuit board. Blown No. A2-2 fuse. Check for an open or short in the wire between the 12 volt battery and the starter. L15BA engin
  • Page 52- Check the transmission range switch. - Check the brake pedal position switch (K20C2 engine). - Check for an open or short in the wire and connectors between the transmission range switch and ground (G201). - Check for an open or short in the wire and connectors between the TCM and the transmission
  • Page 53Check for an open or short in the wire and connectors between the relay circuit board and the starter. Check for an open or short in the wire and connectors between the relay circuit board and PCM. Check for an open or short in the wire and connectors between the body control module and the PCM (STS
  • Page 54following service limit table. Voltage (V) Current (A) 8.5 or more 380 or less Are the cranking voltage and the current draw within the service limits? cardiagn.com
  • Page 55YES Remove the starter, and inspect its drive gear and the flywheel ring gear (M/T) or the torque converter ring gear (CVT) for damage. Replace any damaged parts.■ NO Replace the starter or remove and disassemble it, and check for these problems:■ Excessive drag in the engine Drag in the starter arm
  • Page 56Starter System Circuit Troubleshooting cardiagn.com Starter System Circuit Troubleshooting Special Tools Required Alternator, Regulator, Battery, and Starter Tester OTC3131* *: Available through the Honda Tool and Equipment Program 888-424-6857 NOTE: Air temperature must be between 59-100 °F (15-38
  • Page 57‐2. Check for PGM-FI and Keyless Access system DTCs with the HDS. If you fail to enter the SYSTEM SELECTION MENU with the HDS, go to the keyless access system symptom troubleshooting "Cannot select ON mode with keyless access and with the keyless remote touching the engine start/stop switch". PGM-FI
  • Page 58‐1. Make sure the transmission is in neutral. ‐2. Disconnect the following connector. Starter S terminal 1P connector ‐3. Connect terminals A and B with a jumper wire. Terminal A Starter S terminal 1P connector (male terminal) No. 1 Terminal B 12 volt battery positive terminal cardiagn.com Did the s
  • Page 59YES Check the following items in the order listed until you find the problem in the circuit:■ Check the engine start/stop switch. Check the brake pedal position switch. Check the relay circuit board. Blown No. A1-7 (125 A) fuse, No. A2-2 (30 A) fuse, No. A2-4 (60 A) fuse, No. A3-5 (30 A) fuse, No. A
  • Page 60cardiagn.com ‐2. Do the STARTING TEST, check the cranking voltage and the current draw from the following service limit table. Voltage (V) Current (A) 8.5 or more 380 or less Are the cranking voltage and the current draw within the service limits? YES Remove the starter, and inspect its pinion gear
  • Page 61Starting System Circuit Diagram cardiagn.com
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  • Page 63Starting System Circuit Diagram L15BA engine 1/2 cardiagn.com L15BA engine 2/2
  • Page 64cardiagn.com K20C2 engine
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  • Page 66Starting System Circuit Diagram cardiagn.com
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  • Page 68Starting System Component Location Index cardiagn.com
  • Page 69Starting System Component Location Index cardiagn.com
  • Page 70Starting System Component Location Index cardiagn.com
  • Page 71Starting System Symptom Troubleshooting Index Without keyless access system Symptom Diagnostic procedure Also check for Engine does not crank 1. Check for loose 12 volt battery terminals or M/T: Poor ground connections. at G305 2. CVT: Poor ground Test the 12 volt battery for a low state of charge.
  • Page 72Symptom Diagnostic procedure Also check for Engine is hard to start Do the symptom troubleshooting for engine will not start, Weak or fouled spark engine starts but stalls immediately, or engine is hard to plugs start. Engine cranks slowly 1. Check for loose 12 volt battery terminals or connections.