Section 77 (Starting): Starter: Inspection

WARNING: This page is about a different car, the 2007 Lexus ES 350. However, it is still accessible from the selected car via links, so may be relevant.

INSPECT STARTER ASSEMBLY

CAUTION: Make sure to complete each of the following tests within 5 seconds to prevent the coil from burning out.

Perform pull-in test:
1. Disconnect the lead wire from terminal C.
  
  Fig 1: Locating Lead Wire Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the battery to the magnetic switch as shown in the illustration. Check that the clutch pinion gear moves outward.
  If the clutch pinion gear does not move outward, replace the repair service starter kit.
  
  Fig 2: Connecting Battery To Magnetic Switch
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Perform hold-in test:
1. Disconnect the negative (-) terminal lead from terminal C under the conditions for pull-in test. Check that the pinion gear remains out.
  If the clutch pinion gear moves inward, replace the repair service starter kit.
  
  Fig 3: Disconnecting Negative Terminal Lead From Terminal C
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Inspect clutch pinion gear return:
1. Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear moves inward.
  If the clutch pinion gear does not move inward, replace the repair service starter kit.
Fig 4: Checking Clutch Pinion Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Perform no-load performance test:

Connect the field coil wire to terminal C with the nut. Make sure that the lead is not grounded.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
Clamp the starter in a vise.
Connect the battery and an ammeter to the starter as shown in the illustration.

Check that the starter rotates smoothly and steadily with the clutch pinion gear extended. Check that the ammeter reads the specified current.

Specified current

CURRENT SPECIFICATION

Condition	Specified condition
at 11.5 V	90 A or less

If the result is not as specified, overhaul the starter assembly.

Fig 5: Connecting Battery And Ammeter To Starter

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT MAGNETIC SWITCH ASSEMBLY

Check the plunger.
1. Push in the plunger and check that it returns quickly to its original position.
  If necessary, replace the magnetic switch assembly.
  
  Fig 6: Checking Plunger
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Inspect the resistance of the pull-in coil.

Using an ohmmeter, measure the resistance between terminals 50 and C.

Standard resistance

RESISTANCE SPECIFICATION

Tester connection	Specified condition
Terminal 50 - Terminal C	Below 1 Ω

If the resistance is not as specified, replace the magnetic switch assembly.

Fig 7: Measuring Resistance Between Magnetic Clutch Terminals 50 And C

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Inspect the resistance of the hold-in coil.

Using an ohmmeter, measure the resistance between terminal 50 and switch body.

Standard resistance

RESISTANCE SPECIFICATION

Tester connection	Specified condition
Terminal 50 - Switch body	Below 2 Ω

If the resistance is not as specified, replace the magnetic switch assembly.

Fig 8: Measuring Resistance Between Magnetic Clutch Terminals 50 And Switch Body

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT STARTER ARMATURE ASSEMBLY

Check the commutator surface for dirt or burning. If the surface is dirty or burnt, smooth the surface with 400-grit sandpaper or leather.

Inspect the resistance of the commutator.

Using an ohmmeter, measure the resistance between the segments of the commutator.

Standard resistance

RESISTANCE SPECIFICATION

Tester connection	Specified condition
Segment - Segment	Below 1 Ω

If the resistance is not as specified, replace the starter armature assembly.

Fig 9: Measuring Resistance Between Segments Of Commutator

Using an ohmmeter, measure the resistance between the commutator and armature coil core.

Standard resistance

RESISTANCE SPECIFICATION

Tester connection	Specified condition
Commutator - Armature coil core	10 kΩ or higher

If the resistance is not as specified, replace the starter armature assembly.

Fig 10: Measuring Resistance Between Commutator And Armature Coil Core

Using vernier calipers, measure the commutator depth.
Specified depth: 3.1 mm (0.122 in.)

Maximum depth: 3.8 mm (0.150 in.)

If the depth is greater than the maximum, replace the starter armature assembly.

Fig 11: Identifying Commutator Depth
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY
1. Check the brush length.
  1. Using vernier calipers, measure the brush length.
    Specified length: 9.0 mm (0.354 in.)
    
    Maximum length: 4.0 mm (0.157 in.)
    
    If the length is less than the minimum, replace the starter commutator end frame assembly.
    
    Fig 12: Identifying Brush Length
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the resistance.
  1. Using an ohmmeter, measure the resistance between the positive (+) and negative (-) brushes.
    Resistance: 10 kΩ or higher
    
    If the resistance is not as specified, repair or replace the starter commutator end frame assembly.
    
    Fig 13: Measuring Resistance Between Positive And Negative Brushes
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT STARTER CLUTCH
1. Check the starter clutch.
  1. Rotate the clutch pinion gear counterclockwise and check that it turns freely. Try to rotate the clutch pinion gear clockwise and check that it locks.
    If necessary, replace the starter drive housing assembly.
    
    Fig 14: Inspecting Starter Clutch
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002