SECTION 6D3 - STARTING AND CHARGING

SYSTEM (6VE1 3.5L)

Service Precaution

Starting System

General Description

Diagnosis

Starter

Removal

Installation

Disassembled View

Disassembly

Inspection and Repair

Reassembly

Main Data and Specifications

General Specifications

Torque Specifications

Charging System

General Description

General On-Vehicle Inspection

Generator

Removal

Inspection

Installation

Disassembled View

Disassembly

Inspection and Repair

Reassembly

Bench Test

Main Data and Specifications

Service Precaution

WARNING: THIS VEHICLE HAS A SUPPLEMENTAL

RESTRAINT SYSTEM (SRS). REFER TO THE SRS

COMPONENT AND WIRING LOCATION VIEW IN

ORDER TO DETERMINE WHETHER YOU ARE

PERFORMING SERVICE ON OR NEAR THE SRS

COMPONENTS OR THE SRS WIRING. WHEN YOU

ARE PERFORMING SERVICE ON OR NEAR THE

SRS COMPONENTS OR THE SRS WIRING, REFER

TO THE SRS SERVICE INFORMATION. FAILURE TO

FOLLOW WARNINGS COULD RESULT IN

POSSIBLE AIR BAG DEPLOYMENT, PERSONAL

INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM

REPAIRS.

CAUTION: Always use the correct fastener in the

proper location. When you replace a fastener, use

ONLY the exact part number for that application.

HOLDEN will call out those fasteners that require a

replacement after removal. HOLDEN will also call

out the fasteners that require thread lockers or

thread sealant. UNLESS OTHERWISE SPECIFIED,

do not use supplemental coatings (Paints, greases,

or other corrosion inhibitors) on threaded fasteners

or fastener joint interfaces. Generally, such

coatings adversely affect the fastener torque and

the joint clamping force, and may damage the

fastener. When you install fasteners, use the

correct tightening sequence and specifications.

Following these instructions can help you avoid

damage to parts and systems.

Starting System

General Description

Cranking Circuit

The cranking system consists of a battery, starter motor, ignition (starter) switch, starter relay, etc. These main

components are connected by the starting system wiring harness.

Starter

The cranking system employs a magnetic type reduction starter in which the motor shaft is also used as a pinion

shaft. When the ignition switch is turned to the START position, the contacts of starter solenoid are closed, and the

armature rotates. At the same time, the plunger is attracted, and the pinion is pushed forward by the shift lever to

mesh with the ring gear. The ring gear then rotates to start the engine. When the engine speed is higher than the

pinion, the pinion idles, so that the armature is not driven.

When the engine starts and the ignition switch is returned to the ON position, the plunger returns, the pinion is

disengaged from the ring gear, and the armature stops rotation.

RTW46DXF000101

Diagnosis

Symptom Possible Cause Action

Starter does not run Charging failure Repair charging system

Battery failure Replace battery

Terminal connection failure Repair or replace terminal connector

and/or wiring harness

Starter switch failure Repair or replace starter switch

Starter failure Repair or replace starter

Starter

Removal

1. Disconnect the battery ground cable.

2. Disconnect left heated O2 sensor connector.

3. Remove exhaust front left pipe.

4. Remove dust cover.

5. Disconnect starter wiring connector from terminals

“30" and “50".

6. Remove starter assembly mounting bolts on inside

and outside.

7. Remove starter assembly toward the bottom of

engine.

065RY00050

Legend

(1) Terminal "30"

(2) Terminal "50"

(3) Fixing Bolts

(4) Starter Assembly

Installation

1. Install starter assembly.

2. Install mounting bolts and tighten bolts to specified

torque.

Torque: 40 N⋅m (4.1 kg⋅m/30 lb ft)

3. Reconnect the connectors to terminals “30" and

“50" and tighten Terminal “30" to specified torque.

Torque: 9 N⋅m (0.9 kg⋅m/7 lb ft)

4. Install dust cover.

065RY00050

Legend

(1) Terminal "30"

(2) Terminal "50"

(3) Fixing Bolts

(4) Starter Assembly

5. Install exhaust front left pipe and tighten bolts and

nuts to specified torque.

Stud Nut

Torque: 67 N⋅m (6.8 kg⋅m/49 lb ft)

Nut

Torque: 43 N⋅m (4.4 kg⋅m/32 lb ft)

6. Reconnect heated O2 sensor connector.

7. Reconnect the battery ground cable.

Disassembled View

065R100012

Legend (7) Housing

(1) Lead Wire (8) Over Running Clutch

(2) Through Bolt (9) Return Spring

(3) Yoke Assembly (10) Steel Ball

(4) Yoke Cover (11) Idle Pinion

(5) Brush and Brush Holder (12) Retainer

(6) Armature (13) Magnetic Switch (Solenoid)

Disassembly

1. Remove the lead wire (1) from the magnetic switch.

2. Remove the through bolts (2).

065RY00053

Legend

(1) Lead Wire

(2) Through Bolt

3. Remove the yoke from the assembly.

4. Remove the yoke cover.

5. Use long nose pliers to remove the brush and brush

holder.

065RY00054

065RY00055

Legend

(1) Spring

(2) Brush

6. Remove the armature.

7. Remove the housing.

8. Remove the overrunning clutch from the housing.

065RY00056

9. Remove the return spring from the magnetic switch.

065R100014

10. Remove the steel ball from the overrunning clutch.

065RY00058

11. Remove the idle pinion from the magnetic switch.

065R100015

12. Remove the retainer from the magnetic switch.

065R100016

13. Remove the magnetic switch.

Inspection and Repair

Repair or replace necessary parts if extreme wear or

damage is found during inspection.

Armature

Measure the outer diameter of the commutator and

replace with a new one if it is out of the limit.

Standard: 30 mm (1.1811 in)

Limit: 29 mm (1.1417 in)

065RS014

Check for continuity between segment and segment on

the commutator. Replace commutator if there is no

continuity (i.e., open circuit).

065RS015

Check for continuity between commutator and shaft.

Also, check for continuity between commutator and

armature core, armature core and shaft. Replace

commutator if there is continuity (i.e., internally

grounded).

065RS016

Measure runout of the commutator with a dial gauge.

Repair or replace if it exceeds the limit.

Limit: 0.4 mm (0.0157 in)

065RY00061

If rough, polish the commutator surface with #500 to

#600 sandpaper.

065RW012

Measure the depth of the insulator in the commutator.

Replace, if it is below the limit.

Standard: 0.45 mm to 0.75 mm (0.0177 in to

0.0295 in)

Limit: 0.2 mm (0.008 in)

065RY00070

Legend

(1) Insulator

(2) Depth of Insulator

(3) Commutator Segments

Brush

Measure the length of the brush.

Replace with a new one if it is below the limit.

Standard: 15 mm (0.5906 in)

Limit: 11 mm (0.43 in)

065RW014

Brush Holder

Check for continuity between brush holder (+) (4) and

base (–). Replace if there is continuity (i.e., insulation is

broken).

065RW015

Brush Spring

Use a spring balancer to measure the spring setting

force when removing the spring from the brush.

Standard: 17.65–23.54 N (38.9–51.9 lb)

Limit: 11.77 N (25.9 lb)

Magnetic Switch

Temporarily connect the magnetic switch between the

overrunning clutch and housing.

Perform the steps described below in 3 to 5 seconds.

1. Pull in test.

Connect the ground (-) to terminal “C” and magnetic

switch body.

Verify that the pinion pulls out when the battery (+)

pole is connected to terminal “50”.

065R100017

2. Hold in test.

Observe that the pinion stays when the lead wire is

disconnected from terminal “C”.

065R100018

3. Return test.

Connect the ground (-) to terminal “50” and

magnetic switch body.

Verify that the pinion pulls out when the battery (+)

pole is connected to terminal “C” and the pinion

pulls away when the lead wire is disconnected from

terminal “50”.

065R100019

Field Coil

1. Check for continuity between the end of the field

coil and yoke body.

Replace the field coil if there is continuity.

065RY00065

2. Check continuity between the lead wire of terminal

“C” and brush.

Replace the yoke assembly if there is no continuity.

065RY00066

Overrunning Clutch

1. Visually check for excessive wear or damage.

2. Test the pinion rotation, it must rotate smoothly

when rotated clockwise and it shouldn't rotate when

turned counter clockwise.

065RY00067

Bearing

1. Inspect excessive wear or damage.

Replace the bearing if an abnormal noise is heard

under normal operating condition.

065RY00068

Reassembly

To install, follow the removal steps in the reverse order,

noting the following points:

Grease application places

• Bearing in rear cover

• Gears in reduction gear

• Sliding portion of pinion

Main Data and Specifications

General Specifications

Model ADX4IH

Rating

Voltage 12 V

Output 1.4 Kw

Time 30 sec

Number of teeth of pinion 9

Rotating direction (as viewed from pinion) Clockwise

Weight (approx.) 3.8 kg (8.4 lb)

No–load characteristics

Voltage/current 11.5 V/90 A or less

Speed 3000 rpm or more

Load characteristics

Voltage/current 8.5 V/350 A or less

Torque 13.2 N m (1.35 kg m/9.77 lb in.) or more

Speed 1000 rpm or more

Locking characteristics

Voltage/current 2.4 V/500 A or less

Torque 11.8 N⋅m (1.2 kg⋅m/8.68 lb in) or more

Torque Specifications N⋅m (kg⋅m/lb ft)

RTW46DLF000101

Charging System

General Description

The IC integral regulator charging system and its main components are connected as shown in illustration.

The regulator is a solid state type and it is mounted along with the brush holder assembly inside the generator

installed on the rear end cover.

The generator does not require particular maintenance such as voltage adjustment.

The rectifier connected to the stator coil has eight diodes to transform AC voltage into DC voltage.

This DC voltage is connected to the output terminal of generator.

General On–Vehicle Inspection

The operating condition of charging system is indicated by the charge warning lamp. The warning lamp comes on

when the starter switch is turned to the “ON" position. The charging system operates normally if the lamp goes off

when the engine starts.

If the warning lamp shows abnormality or if undercharged or overcharged battery condition is suspected, perform

diagnosis by checking the charging system as follows:

1. Check visually the belt and wiring connector.

2. With the engine stopped, turn the ignition switch to the “ON" position and observe the warning lamp.

If lamp does not come on:

Disconnect the wiring connector from generator, and ground terminal “L" on connector side.

If lamp comes on: Repair or replace the generator.

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Generator

Removal

1. Disconnect the battery ground cable.

2. Move drive belt tensioner to one side using wrench

then remove drive belt (1).

3. Disconnect the wire from terminal “B" and

disconnect the connector (4).

4. Remove generator fixing bolt (3).

5. Remove generator assembly (2).

060RW002M

Inspection

1. Disconnect the wiring connector from the generator.

2. With the engine stopped, turn starter switch to the

“ON" position and connect a voltmeter between

connector terminal L (2) and ground or between

terminal IG (1) and ground.

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If voltage is not present, the line between battery

and connector is open circuit and will require repair.

3. Reconnect the wiring connector to the generator,

run the engine at middle speed, and turn off all

electrical devices other than engine.

4. Measure battery voltage. If it exceeds 16V, repair or

replace the generator.

5. Connect an ammeter to output terminal of

generator, and measure output current under load

by turning on the other electrical devices (eg.,

headlights). At this time, the voltage must not be

less than 13V.

Installation

1. Place generator assembly in the position to be

installed.

2. Install generator assembly and tighten the fixing

bolts to the specified torque.

Torque:

M10 bolt: 52 N⋅m (5.3 kg⋅m/38 lb ft)

M8 bolt: 25 N⋅m (2.5 kg⋅m/18 lb ft)

3. Connect wiring harness connector and connect wire

to terminal “B".

4. Move drive belt tensioner to one side using wrench,

then install drive belt to normal position.

5. Reconnect the battery ground cable.

Disassembled View

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Legend (6) Rectifier

(1) Pulley Nut (7) Terminal Insulator and Nut

(2) Pulley (8) Regulator Assembly

(3) Front Cover Assembly (9) Brush Holder Assembly

(4) Rotor Assembly (10) Rear Cover

(5) Rear End Cover

Disassembly

1. Remove terminal insulator and nut (2).

2. Remove three nuts (1) on the rear cover, then

remove the rear cover (3).

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3. Remove two screws that fix the brush holder (5)

and rectifier, then remove the brush holder

assembly (4).

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4. Remove three screws that fix the IC regulator, then

remove the IC regulator assembly (6).

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5. Remove the four screws that fix the rectifier (7) and

stator lead wires.

066RW004

6. Secure the pulley directly in the vise between two

copper plates, and remove the nut and pulley.

066RS010

7. Remove the four nuts (8) that secure the front cover

assembly, rear end cover and an insulator (9).

066RW005

8. Use the puller to remove the rear end cover.

066RS012

9. Remove the rotor assembly (10) from the front

cover assembly (12) by using a bench press (11).

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Inspection and Repair

Repair or replace necessary parts if extreme wear or

damage is found during inspection.

Rotor Assembly

1. Check the rotor slip ring surfaces for contamination

and roughness. If rough, polish with #500 to 600

sandpaper.

066RS014

2. Measure the slip ring diameter, and replace if it

exceeds the limit.

066RS015

3. Measure resistance between slip rings, and replace

the rotor assembly if there is no continuity.

066RS016

4. Measure resistance between slip ring and rotor

core.

If there is continuity, replace the rotor assembly.

066RS017

Stator Coil

1. Measure resistance between respective phases.

2. Measure insulation resistance between stator coil

and core with a mega–ohmmeter.

If less than standard, replace the coil.

066RS018

Brush

Measure the brush length.

If less than limit, replace the brush.

Standard: 10.mm (0.4134 in)

Limit: 8.4.mm (0.3307 in)

066RS019

Rectifier Assembly

Check for continuity across terminals “P" and “E" using

the  100W range of the multimeter.

066RW002

Change polarity, and make sure that there is continuity

in one direction, and not in the reverse direction. In

case of continuity in both directions, replace the rectifier

assembly.

IC Regulator Assembly

Check for continuity across terminals “B" and “F" using

the  100W range of the multimeter.

066RS021

Change polarity, and make sure that there is continuity

in one direction, and not in the reverse direction. In

case of continuity in both directions, replace the IC

regulator assembly.

Reassembly

To reassemble, follow the disassembly steps in the

reverse order, noting the following points:

1. Using a press with a socket wrench attached,

reassemble the rotor and the rear end cover

assembly into the front cover.

066RS022

2. Install pulley on the rotor.

Secure the pulley directly in the vise between two

copper plates, and tighten nut to the specified

torque.

Torque: 111 N⋅m (11.3 kg⋅m/82 lb ft)

066RS010

Bench Test

Conduct a bench test of the generator.

066RS023

Preparation

Remove generator from the vehicle (see “Generator

Removal").

1. Secure generator to the bench test equipment and

connect wires as follows:

Terminal “IG" for energization.

Terminal “L" for neutral (warning lamp).

Terminal “B" for output.

2. Conduct the generator characteristic test.

Characteristics of generator are shown in

illustration.

Repair or replace the generator if its outputs are

abnormal.

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Main Data and Specifications

General Specifications

Part number 102211-1740

Model ACJV74

Rated voltage 12 V

Rated output 90 A

Rotating direction (as viewed from pulley) Clockwise

Pulley effective diameter 57.5 mm (2.26 in)

Weight 5.1 kg (11 lb)