Description	Unit	1.2 DOHC (B12D)	1.4 DOHC - G14D
Type	-	Permanent Magnet Straight Drive	PG 260C (G3)
Output (Capacity)	kW	0.8	1.2
Drive Pinion Speed (No Load Test @ 12 volts Condition)	RPM	4,845 Min	2,800 Min
Brushes length	mm (in.)	11.4 (0.448)	8.25 (0.325)

Description	Unit	1.2 DOHC (B12D)	1.4 DOHC - G14D
Type	-	NP08	NP/OH
System Voltage	V	12	12
Brushes length	mm (in.)	18.8 (0.74)	18.8 (0.740)
Output (Capacity)	A	80	95

Description	Unit	1.2 DOHC (B12D)	1.4 DOHC - G14D
Capacity	AH	45	50
Cold Cranks Amps	CCA	430	550
Reserve Capacity Minimum	min	80	90
Load Test	amps	200	270
Minimum Voltage:	-	-	-
9.6	V	70°F (21°C) and above	70°F (21°C) and above
9.5	V	60°F (15.6°C)	60°F (15.6°C)
9.4	V	50°F (10°C)	50°F (10°C)
9.3	V	40°F (4.4°C)	40°F (4.4°C)
9.1	V	30°F (-1.1°C)	30°F (-1.1°C)
8.9	V	20°F (-6.7°C)	20°F (-6.7°C)
8.7	V	10°F (-12.2°C)	10°F (-12.2°C)
8.5	V	0°F (-17.8°C)	0°F (-17.8°C)

Application	N•m	Lb-Ft	Lb-In
Battery Cable Nuts	4.5	-	40	.
Battery Carrier Tray Lower Bolts	20	15	-
Battery Carrier Tray Upper Bolts	20	15	-
Battery Retainer Clamp-to-Battery Rod Nuts	4	-	35
Fuel Rail Retaining Bolts	20	15	-
Generator Battery Lead Nut	15	11	-
Generator Drive End Bearing Nut	81	60	-
Generator Lower Bracket-to-Generator Nuts	25	18	-
Generator Pulley Retaining Nut	95	70	-
Generator Rear Cover Retaining Nut (B12D)	16.5	12.1	-
Generator Rear Cover Retaining Nut (G14D)	18.5	13.6	-
Generator Retaining Bolt/Nut (B12D)	25	18.4	-
Generator Retaining Bolt/Nut (G14D)	35	25.8	-
Generator Shackle Bracket Bolt	25	18	-
Generator Through-Bolts (G12D)	4.75	3.5	-
Generator Through-Bolts (G14D)	4.75	3.5	-
Starter Field Coil Connector Nut	8	-	71
Starter Mounting Bolts (G12D)	23	17	-
Starter Mounting Bolts (G14D)	25	18.4	-
Starter Solenoid Nuts	10.5	7.7	-

1. Starter Motor Assembly
2. Starter Solenoid Assembly
3. Starter Housing
4. Shift Lever
5. Armature Set
6. Armature
7. Pinion Gear Assembly
8. Ring Set
9. Field Frame Assembly
10. Brush Holder Assembly
11. Contact End Frame Assembly
12. Starter Through - Bolts

1. Starter Motor Assembly
2. Starter Solenoid Assembly
3. Starter Housing
4. Shift Lever
5. Armature Set
6. Armature
7. Pinion Gear Assembly
8. Ring Set
9. Field Frame Assembly
10. Brush Holder Assembly
11. Contact End Frame Assembly
12. Starter Through - Bolts

1. Generator Assembly
2. Generator Shackle
3. Generator Drive End Nut
4. Generator Pully
5. Generator Collar (Large)
6. Generator Front Bracket
7. Front Bearing
8. Bearing Spot Plate
9. Generator Collar (Small)
10. Generator Rotor Assembly
11. Rear Bearing
12. Generator Stator Assembly
13. Rectifier Assembly
14. Voltage Regulator/Brush Holder Assembly
15. Generator Rear Bracket
16. Battery Positive Terminal Nut
17. Through Bolt

1. Generator Assembly
2. Generator Drive End Nut
3. Generator Pully
4. Generator Collar
5. Generator Front Bracket
6. Front Bearing
7. Generator Stator Assembly
8. Fan
9. Generator Rotor Assembly
10. Generator Rear Bracket
11. Rectifier Assembly
12. Cover
13. Voltage Regulator/Brush Holder Assembly

Step	Action	Value(s)	Yes	No
1	Press the clutch pedal completely down. Turn the key to START. Does the vehicle start?	-	System OK	Go to Step 2
2	Disconnect the clutch pedal position switch wires. Check for continuity between the switch terminals when the clutch pedal switch is pushed to the ON position. Does the ohmmeter indicate the value specified?	-	Go to Step 4	Go to Step 3
3	Replace the clutch pedal position switch. Does the vehicle start?	-	System OK	Go to Step 4
4	Turn the headlamps ON. Turn the dome lamps ON. Turn the key to START. Do the lights dim or go out?	-	Go to Step 5	Go to Step 11
5	Check the battery state of charge. Is the green eye showing from the built-in hydrometer?	-	Go to Step 6	Go to "Charging Procedure"
6	Connect the voltmeter positive lead to the positive battery terminal. Connect the voltmeter negative lead to the negative battery terminal. Turn the ignition to START. Does the voltmeter indicate the value specified?	< 9.6 v	Go to "Charging Procedure"	Go to Step 7
7	Connect the voltmeter negative lead to the negative battery terminal. Connect the voltmeter positive lead to the engine block. Place the ignition in the START position. Is the repair complete?	> 0.5 v	Go to Step 8	Go to Step 9
8	Clean and tighten the negative battery cable connections both at the battery end and at the ground end. Replace the cable if needed. Is the repair complete?	-	System OK	-
9	Connect the voltmeter positive lead to the starter "B" terminal. Connect the voltmeter negative lead to the negative battery terminal. Check the cranking voltage. Does the voltmeter indicate the value specified?	< 9 v	Go to Step 10	Go to Step 16
10	Clean, tighten, or replace the positive battery cable. Is the repair complete?	-	System OK	-
11	Check system fuse EF3 in the engine fuse block. Is fuse EF3 blown?	-	Go to Step 12	Go to Step 13
12	Replace system fuse EF3. Is the repair complete?	-	System OK	-
13	Check the connection at the starter "S" terminal. Is the connection in good condition?	-	Go to Step 15	Go to Step 14
14	Repair the starter "S" terminal. Is the repair complete?	-	System OK	-
15	Connect the voltmeter positive lead to the starter "S" terminal. Connect the voltmeter negative lead to the negative battery terminal. Place the ignition in the START position. Read the voltage present at the "S" terminal. Does the voltmeter indicate the specified value?	> 7 v	Go to Step 16	Go to Step 17
16	Repair or replace the starter. Is the repair complete?	-	System OK	-
17	Turn on the heater blower. Does the blower operate?	-	Go to Step 27	Go to Step 18
18	Disconnect connector C204. Connect the voltmeter positive lead to terminal 1 of connector C204. Connect the voltmeter negative terminal to ground. Does the voltmeter indicate the specified value?	12 v	Go to Step 20	Go to Step 19
19	Repair the open in the RED/WHT wire from fuse EF3 to Connector C204. Is the repair complete?	-	System OK	-
20	Check the contacts of terminal 1 on connector C204. Are the contacts OK?	-	Go to Step 22	Go to Step 21
21	Repair the faulty contact of connector C204. Is the repair complete?	-	System OK	-
22	Reconnect connector C204. Disconnect the ignition switch connector. Connect the voltmeter positive lead to terminal 5 of the ignition switch connector. Connect the voltmeter negative terminal to ground. Does the voltmeter indicate the specified value?	11-14 v	Go to Step 24	Go to Step 23
23	Repair the open in the RED/WHT wire from terminal 1 of connector C204 to terminal 5 of the ignition switch connector. Is the repair complete?	-	System OK	-
24	Check the contacts of terminal 5 of the ignition switch connector. Are the contacts OK?	-	Go to Step 26	Go to Step 25
25	Repair the faulty contact of the ignition switch connector. Is the repair complete?	-	System OK	-
26	Replace the ignition switch. Is the repair complete?	-	System OK	-
27	Disconnect connector C205. Connect the voltmeter positive lead to terminal 1 of connector C205 on the I/P harness. Connect the voltmeter negative lead to ground. Turn the ignition switch to START. Does the voltmeter indicate the specified value?	12 v	Go to Step 28	Go to Step 31
28	Check terminal 1 on both sides of connector C205. Is one of them faulty?	-	Go to Step 29	Go to Step 30
29	Repair the faulty terminal. Is the repair complete?	-	System OK	-
30	Repair the open in the YEL wire from terminal 1 of connector C205 to the starter "ST" terminal. Is the repair complete?	-	System OK	-
31	Disconnect the ignition switch connector. Connect the voltmeter positive lead to terminal ST of the ignition switch. Connect the voltmeter negative lead to ground. Turn the ignition switch to START. Does the voltmeter indicate the specified value?	12 v	Go to Step 33	Go to Step 32
32	Replace the ignition switch. Is the repair complete?	-	System OK	-
33	Check terminal ST on the ignition switch and terminal 3 of the ignition switch connector. Are the terminals in good condition?	-	Go to Step 34	Go to Step 35
34	Repair the open in RED wire between terminal 3 of the ignition switch connector and terminal 1 of connector C205. Is the repair complete?	-	System OK	-
35	Repair the faulty terminal. Is the repair complete?	-	System OK	-

Checks	Action
Check for a high-pitched whine during cranking, before the engine fires. The engine cranks and fires properly.	The distance is too great between the starter pinion and the flywheel. Shimming the starter toward the flywheel is required.
Check for a high-pitched whine after the engine fires, as the key is being released. The engine cranks and fires properly. This intermittent complaint is often diagnosed as "starter hang-in" or "solenoid weak."	The distance is too small between the starter pinion and the flywheel. Shimming the starter away from the flywheel is required.
Check for a loud "whoop" after the engine fires but while the starter is still held engaged. The sound is like a siren if the engine is revved while the starter is engaged.	The most probable cause is a defective clutch. A new clutch will often correct this problem.
Check for a "rumble," a "growl," or, in severe cases, a "knock" as the starter is coasting down to a stop after starting the engine.	The most probable cause is a bent or unbalanced starter armature. A new armature will often correct this problem.

1. Check for a bent or a worn flywheel.
2. Start the engine and carefully touch the outside diameter of the rotating flywheel ring gear with chalk or a crayon to show the high point of the tooth runout. Turn the engine OFF and rotate the flywheel so that the marked teeth are in the area of the starter pinion gear.
3. Disconnect the negative battery cable to prevent cranking the engine.
4. Check the pinion-to-flywheel clearance by using a wire gauge of 0.5 mm (0.02 inch) minimum thickness (or diameter). Center a pinion tooth between two flywheel teeth and the gauge. Do not gauge in the corners, where a misleading larger dimension may be observed. If the clearance is under this minimum, shimming the starter away from the flywheel is required.
5. If the clearance approaches 1.5 mm (0.06 inch) or more, shimming the starter toward the flywheel is required. This condition is generally the cause of broken flywheel teeth or the starter housing. Shim the starter toward the flywheel by shimming only the outboard starter mounting pad. A shim of 0.40 mm (0.016 inch) thickness at this location will decrease the clearance by approximately 0.30 mm (0.012 inch). If normal starter shims are not available, plain washers or other suitable material may be used as shims.

1. Check the battery for obvious damage, such as a cracked or broken case or cover, which could permit the loss of electrolyte. If obvious damage is noted, replace the battery.
2. Check the battery for obvious damage, such as a cracked or broken case or cover, which could permit the loss of electrolyte. If obvious damage is noted, replace the battery.

2. Check the hydrometer. If the green dot is visible, go to the load test procedure. If the indicator is dark but green is not visible, charge the battery. For charging a battery removed from the vehicle, refer to "Charging a Completely Discharged Battery" in this section.
3. Check the hydrometer. If the green dot is visible, go to the load test procedure. If the indicator is dark but green is not visible, charge the battery. For charging a battery removed from the vehicle, refer to "Charging a Completely Discharged Battery" in this section.
4. Connect a voltmeter and a battery load tester across the battery terminals.
5. Apply a 300-ampere load for 15 seconds to remove any surface charge from the battery.
6. Remove the load.
7. Wait 15 seconds to let the battery recover, and apply a 270-ampere load.

7. If the voltage does not drop below the minimum listed, the battery is good and should be reinstalled. If the voltage is less than the minimum listed, replace the battery. Refer to "Battery Specifications" in this section.
8. If the voltage does not drop below the minimum listed, the battery is good and should be reinstalled. If the voltage is less than the minimum listed, replace the battery. Refer to "Battery Specifications" in this section.

1. Perform the generator system test. Refer to "Generator System Check"in this section.
2. Perform the generator system test. Refer to "Generator System Check"in this section.
3. Replace the generator if it fails that test. Refer to "Generator" in the On-Vehicle Service portion of this section. If it passes the test, perform the on-vehicle output check which follows.

3. Attach a digital multimeter, an ammeter, and a carbon pile load to the vehicle.
4. Attach a digital multimeter, an ammeter, and a carbon pile load to the vehicle.

4. With the ignition switch in the OFF position, check and record the battery voltage.
5. With the ignition switch in the OFF position, check and record the battery voltage.
6. Remove the harness connector from the generator.
7. Turn the ignition to RUN with the engine not running. Use a digital multimeter to check for voltage in the harness connector "L" terminal.
8. The reading should be near the specified battery voltage of 12 volts. If the voltage is too low, check the indicator “L” terminal circuits for open and grounded circuits causing voltage loss. Correct any open wires, terminal connections, etc., as necessary. Refer to "Charging System" in this section.
9. Attach the generator harness connector.
10. Run the engine at a moderate idle, and measure the voltage across the battery terminals. The reading should be above that recorded in step 14, but less than 16 volts. If the reading is over 16 volts or below the previous reading, replace the generator. Refer to "Generator" in the On-Vehicle Service section.
11. Run the engine at a moderate idle, and measure the generator amperage output.
12. Turn on the carbon pile, and adjust it to obtain the maximum amps while maintaining the battery voltage above 13 volts.
13. If the reading is within 15 amps of the generator’s rating noted on the generator, the generator is good. If not, replace the generator. Refer to "Generator" in the On-Vehicle Service section.
14. With the generator operating at the maximum output, measure the voltage between the generator housing and the battery negative terminal. The voltage drop should be 0.5 volt or less. If the voltage drop is more than 0.5 volt, check the ground path from the generator housing to the negative battery cable.
15. Check, clean, tighten, and recheck all of the ground connections.

1. Visually check the belt and the wiring.
2. With the ignition in the ON position and the engine stopped, the charge indicator lamp should be on. If not, detach the harness at the generator and ground the "L" terminal in the harness with a 5-ampere jumper lead.
• If the lamp lights, replace the generator. Refer to "Generator" in the On-Vehicle Service section.
• If the lamp does not light, locate the open circuit between the ignition switch and the harness connector. The indicator lamp bulb may be burned out.

2. With the ignition switch in the ON position and the engine running at moderate speed, the charge indicator lamp should be off. If not, detach the wiring harness at the generator.
3. With the ignition switch in the ON position and the engine running at moderate speed, the charge indicator lamp should be off. If not, detach the wiring harness at the generator.
• If the lamp goes off, replace the generator. Refer to "Generator" in the On-Vehicle Service section.
• If the lamp stays on, check for a short to ground in the harness between the connector and the indicator lamp.