Starting System

Starter Brush Inspection

Measure the brush length. If not within the service limit, replace the armature housing and brush holder assembly.
Brush Length

	Standard (NEW)	Service Limit
Hitachi	14.5-15.5 mm (0.57-0.61 in)	11.0 mm (0.43 in)
Nippondenso	13.0-13.5 mm (0.51 -0.53 in)	8.5 mm (0.33 in)
Mitsuba	14.3-14.7 mm (0.56-0.58 in)	9.3 mm (0.37 in)

NOTE: To seat new brushes after installing them in their holders, slip a strip of #500 or #600 sandpaper, with the grit side up, over the commutator and smoothly rotate the armature. The contact surface of the brushes will be sanded to the same contour as the commutator.

Solenoid Plunger Inspection (Nippondenso)

Check the contact points and the face of the starter solenoid plunger for burning, pitting or any other defects. If surfaces are rough, recondition them with a strip of #500 or #600 sandpaper.