FixVault
Home › Subaru › 2020 › BRZ Limited, Automatic Trans › Repair and Diagnosis › Engine Mechanical › Starter › Engine Starting System › Starting System (FA20) › On-Vehicle Inspection

On-Vehicle Inspection

NOTE:
  • The following check is performed with the starter mounted on the vehicle to measure the contact condition of starter magnet switch contact (hereinafter referred to as contact) electrically during engine cranking for check.
  • If the contact is faulty, its contact resistance is too high and the time required for the contact to switch ON completely is long.
  1. Starter ASSY check
    1. Contact resistance measurement method
      NOTE:
      • With the contact resistance measurement method, the resistance when the starter is energized is measured and the resistance increases when the contact is worn and its contact condition degrades.
      • Since the contact resistance cannot be measured directly, it is calculated from the starter driving current and the voltage between the terminals.
      1. Check the DTC. (Refer to MALFUNCTION SYMPTOMS AND DTC CHECK )
        CAUTION: When a diagnostic code is detected, perform troubleshooting by code.
      2. Move the lock lever in the direction of arrow to unlock the three connectors.

        Disconnect the three connectors with lock and normal connector from the injector driver.

        G12586831Courtesy of SUBARU OF AMERICA, INC.
        G12587221Courtesy of SUBARU OF AMERICA, INC.
      3. Remove the three bolts and remove the injector driver.
      4. Remove the chamber. (Refer to REMOVAL )
        G12587222Courtesy of SUBARU OF AMERICA, INC.
      5. Remove the 2 bolts, and remove the intake manifold protector (bank 1 side).
        G12587223Courtesy of SUBARU OF AMERICA, INC.
      6. Disconnect the two connectors of fuel injector.
      7. Install the intake manifold protector (bank 1 side) with the two bolts.

        Standard value:T=19N.m {194kgf.cm} {14.0ft.lbf} 

        G12587224Courtesy of SUBARU OF AMERICA, INC.
      8. Install the injector driver with the three bolts.

        Standard value:T=6.4N.m {65kgf.cm} {4.7ft.lbf} 

        NOTE: Leave the two upper connectors of injector driver disconnected.
        G12587225Courtesy of SUBARU OF AMERICA, INC.
      9. Remove the 2 bolts, and remove the intake manifold protector (bank 2 side).
        G12587226Courtesy of SUBARU OF AMERICA, INC.
      10. Disconnect the two connectors of fuel injector.
        G12587227Courtesy of SUBARU OF AMERICA, INC.
      11. Measure the starter driving current while cranking at the position A in the figure five times. Calculate the average and record it.
        NOTE:
        • Since the current generated by the generator may be measured depending on the measurement position, make sure that the current displayed on the electrical tester is within the range shown in the table and the starter driving current is measured properly.
          STARTER DRIVING CURRENT

          Starter driving current Starter output
          100 to 180 A 1.0 kW (transmission MT)
          1.6 kW (transmission AT)
        • The starter driving current in the table indicates the reference value when the engine is hot.
        • Perform the cranking for about 2 seconds and then read the value when the current indicated on the circuit tester stabilizes.
        • Since the vehicle with the smart entry & start system is equipped with the cranking hold control, cranking is continued for a certain period of time when the engine does not start. To stop cranking, press the push button start switch again.
        G12587228Courtesy of SUBARU OF AMERICA, INC.
      12. Disconnect the battery ground terminal. (Refer to WORKING PRECAUTIONS AND NOTES )
      13. Set the digital tester between the starter terminal M and engine wiring No. 2.
        G12587229Courtesy of SUBARU OF AMERICA, INC.
        CAUTION: Be careful not to short the terminal +B.
        NOTE: Attach alligator clips to the leads of electrical tester and secure them on the terminal M and the battery positive terminal side.
      14. Reconnect the battery ground terminal.

        Standard value:T=6.0N.m {61kgf.cm} {4.4ft.lbf} 

      15. Measure the voltage between the starter terminal M and engine wiring No. 2 while cranking 20 times.
        G12587230Courtesy of SUBARU OF AMERICA, INC.
        CAUTION:
        • Be careful not to short the terminal +B.
        • If the starter cannot be stopped while the measurement, remove the battery negative terminal to stop the starter, and then check the push button start switch or ignition (starter) switch ASSY, starter relay, starter ASSY and wiring harness. Replace the faulty parts.
        NOTE:
        • Since the contact conditions of moving contacts and fixed contacts vary during the operation, it is necessary to measure about 20 times.
        • Perform the cranking for about 2 seconds and then read the value when the voltage indicated on the circuit tester stabilizes.
        • Since the vehicle with the smart entry & start system is equipped with the cranking hold control, cranking is continued for a certain period of time when the engine does not start. To stop cranking, press the push button start switch again.
        G12587231Courtesy of SUBARU OF AMERICA, INC.
      16. Calculate the voltage between the starter terminals from the measurement values above.

        How to calculate the standard value

        Standard value (mV) = 2.5 mΩ (Starter criteria resistance) xAverage value of starter driving current

        Calculation example

        Average value of starter driving current: 120 A

        Starter criteria resistance (2.5 mΩ)

        120 x2.5 = 300, and the standard value is 300 mV or less.

        Standard value: Measurement voltage (mV) is equal to or less than standard value (mV).

        NOTE: Replace the starter contact if the measurement value exceeds the standard value even once among the 20 measurements.
      17. Disconnect the battery ground terminal. (Refer to WORKING PRECAUTIONS AND NOTES )
        G12587232Courtesy of SUBARU OF AMERICA, INC.
      18. Remove the three bolts and remove the injector driver.
        G12587233Courtesy of SUBARU OF AMERICA, INC.
      19. Remove the 2 bolts, and remove the intake manifold protector (bank 1 side).
        G12587234Courtesy of SUBARU OF AMERICA, INC.
      20. Connect the two connectors of fuel injector.
      21. Using 2 bolts, install the intake manifold protector (bank 1 side).

        Standard value: T=19N.m {194kgf.cm} {14.0ft.lbf} 

      22. Install the chamber. (Refer to INSTALLATION )
        G12587235Courtesy of SUBARU OF AMERICA, INC.
      23. Install the injector driver with the three bolts.

        Standard value: T=6.4N.m {65kgf.cm} {4.7ft.lbf} 

        G12587236Courtesy of SUBARU OF AMERICA, INC.
      24. Connect the three connectors with lock to the injector driver. Move the lock lever as shown in the figure to lock the three connectors with lock.
        G12587237Courtesy of SUBARU OF AMERICA, INC.
        CAUTION: For connector with lock, connect the connector securely to lock it.
        G12587238Courtesy of SUBARU OF AMERICA, INC.
      25. Connect the two connectors of fuel injector.
        G12587239Courtesy of SUBARU OF AMERICA, INC.
      26. Using 2 bolts, install the intake manifold protector (bank 2 side).

        Standard value: T=19N.m {194kgf.cm} {14.0ft.lbf} 

        (aa) Reconnect the battery ground terminal.

        Standard value: T=6.0N.m {61kgf.cm} {4.4ft.lbf} 

        (ab) Make sure that there is no influence on the engine startability and after the engine is started.

About FixVault