Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 201
1I-12 Starting System: For Diesel Engine Model
Diagnostic Information and Procedures
Cranking System Symptom Diagnosis
S6JB0A1924001
Possible symptoms due to 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,
(including starting motor switch), starting motor or engine.
Do not remove motor just because starting motor does not run. Check the following items and narrow down scope of
possible causes.
1) Condition of trouble
2) Tightness of battery terminals (including ground cable connection on engine side) and starting motor terminals
3) Discharge of battery
4) Mounting of starting motor
Condition
Possible cause
Correction / Reference Item
Motor not running – No
operating sound of
magnetic switch
Battery run down
Recharge battery.
Battery voltage too low due to battery
deterioration
Replace battery.
Poor contact in battery terminal
connection
Retighten or replace.
Loose grounding cable connection
Retighten.
Fuse set loose or blown off
Tighten or replace.
Poor contacting action of ignition switch
and magnetic switch
Replace.
Lead wire coupler loose in place
Retighten.
Open-circuit between ignition switch and
magnetic switch
Repair.
Open-circuit in pull-in coil
Replace magnetic switch.
Brushes are seating poorly or worn
down
Repair or replace.
Poor sliding or plunger and/or pinion
Repair.
Motor not running –
Operating sound of
magnetic switch heard
Battery run down
Recharge battery.
Battery voltage too low due to battery
deterioration
Replace battery.
Loose battery cable connections
Retighten.
Burnt main contact point, or poor
contacting action of magnetic switch
Replace magnetic switch.
Brushes are seating poorly or worn
down
Repair or replace.
Weakened brush spring
Replace starting motor.
Burnt commutator
Replace starting motor.
Layer short-circuit of armature
Replace starting motor.
Crankshaft rotation obstructed
Repair.
Starting motor running,
but too slow (small
torque) – Battery and
wiring are satisfactory
Insufficient contact of magnetic switch
main contacts
Replace magnetic switch.
Layer short-circuit of armature
Replace starting motor.
Disconnected, burnt or worn
commutator
Replace starting motor.
Worn brushes
Replace starting motor.
Weakened brush springs
Replace starting motor.
Burnt or abnormally worn end bush
Replace starting motor.
Starting motor running,
but not cranking engine
Worn pinion tip
Replace over-running clutch.
Poor sliding of over-running clutch
Repair.
Over-running clutch slipping
Replace over-running clutch.
Worn teeth of ring gear
Replace flywheel (M/T).
Starting System: For Diesel Engine Model 1I-13
Starting Motor Performance Test
S6JB0A1924002
CAUTION
!
Each test must be performed within 3 – 5
seconds to avoid coil from burning.
Pull-In Test
1) Connect battery to magnetic switch as shown.
2) Check that plunger and pinion move outward. If
plunger and pinion don’t move, replace magnetic
switch.
NOTE
Before testing, disconnect lead wire from
terminal “M”.
Hold-In Test
1) While connected as above with plunger out,
disconnect negative lead (2) from terminal “M” (1).
2) Check that plunger and pinion remain out. If plunger
and pinion return inward, replace magnetic switch.
Plunger and Pinion Return Test
1) Disconnect negative lead (1) from switch body (2).
2) Check that plunger and pinion return inward. If
plunger and pinion don’t return, disassemble and
inspect starting motor.
Noise
Abnormally worn bearing
Replace front housing.
Worn pinion or worn teeth of ring gear
Replace over-running clutch or flywheel (M/T).
Poor sliding of pinion (failure in return
movement)
Repair or replace.
Worn internal or planetary gear teeth
Replace.
Lack of oil in each part
Lubricate.
Starting motor does not
stop running
Fused contact points of magnetic switch Replace magnetic switch.
Short-circuit between turns of magnetic
switch coil (layer short-circuit)
Replace magnetic switch.
Failure of returning action in ignition
switch
Replace.
Condition
Possible cause
Correction / Reference Item
1. Terminal “S”
2. Terminal “M”
3. Lead wire (switch to motor)
1
2
3
I5JB0B190002-01
1
2
I5JB0B190003-01
2
1
I5JB0B190004-01
1I-14 Starting System: For Diesel Engine Model
No-Load Performance Test
1) Connect battery and ammeter to starter as shown.
2) Check that starter rotates smoothly and steadily with
pinion moving out. Check that ammeter indicates
specified current.
Specified current (no-load performance test)
90A MAX. at 11V
NOTE
Use wires as thick as possible and tighten
each terminal fully.
Repair Instructions
Starting Motor Components
S6JB0A1926005
A
I5JB0B190005-01
(a)
2
6
5
7
8
9
12
11
13
14
1
15
I5JB0B190006-02
1. Front housing
5. Planetary carrier shaft assembly
9. Pin
13. Over-running clutch
2. Yoke
6. Plunger / lever assembly
10. Magnetic switch inner bolt
14. Pinion stop ring
Starting System: For Diesel Engine Model 1I-15
Starting Motor Dismounting and Remounting
S6JB0A1926001
WARNING
!
To avoid danger of being burned, do not
service exhaust system while it is still hot.
Service should be performed after system
cools down.
1) Disconnect negative (–) cable at battery.
2) Remove air cleaner outlet hose.
3) Remove catalytic converter referring to “Exhaust
System Components: For Diesel Engine Model in
Section 1K”.
4) Disconnect magnetic switch lead wire (3) and battery
cable (4) from starting motor terminals.
5) Remove 3 starting motor mount bolts (2).
6) Remove starting motor (1).
7) To install, reverse the above procedure.
Starting Motor Disassembly and Assembly
S6JB0A1926002
Disassembly
NOTE
Do not clamp yoke in a vise or strike it with a
hammer during repair operations.
1) Disconnect lead wire from terminal “M” (1).
2) Loosen through bolts (2).
3) Loosen magnetic switch screw (1) and then remove
front housing (2).
4) Put match marks (1) on magnetic switch (2) and
planetary carrier shaft assembly (3) to install the
magnetic switch correctly in position.
5) Loosen magnetic switch inner screw (4) and then
remove magnetic switch (2) and spring (5).
CAUTION
!
Don’t disassemble this switch. If defective,
replace as a complete assembly.
6) Remove pin (1) and then remove from lever (2) and
then plunger / lever assembly.
3. Magnetic switch bolt
7. Spring
11. Nut
15. Snap ring
4. Through bolt
8. Magnetic switch
12. Washer
: Do not reuse.
: 55 N
⋅m (5.5 kg-m, 40.0 lb-ft)
: 8 N
⋅m (8.0 kg-m, 6.0lb-ft)
(a)
(a)
2,
2,
1
(b)
3
4
I5JB0B190007-01
1
2
I5JB0B190008-01
1
2
I5JB0B190009-01
1
2
3
4
4
5
I5JB0B190010-01
1
2
I5JB0B190011-01
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