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STARTER (For AWD): Inspection: Inspection

  1. INSPECT STARTER ASSEMBLY 
    NOTE: The following tests must be performed for no more than 5 seconds to prevent the coil from burning out.
    1. Perform the pull-in test.
      1. Disconnect the field coil wire from terminal C.
      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 starter magnetic switch assembly.

        Fig 1: Connecting Battery To Magnetic Switch
        GTY286793Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Perform the hold-in test.
      1. Disconnect the negative (-) terminal lead from terminal C with the condition specified in the pull-in test above being maintained. Check that the pinion gear remains out.

        If the clutch pinion gear moves inward, replace the starter magnetic switch assembly.

        Fig 2: Checking Pinion Gear Remains Out
        GTY256342Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Inspect the 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 starter magnetic switch assembly.

        Fig 3: Inspecting Clutch Pinion Gear Return
        GTY287014Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Perform the no-load performance test.
      1. Connect the field coil wire to terminal C with the nut. Make sure that the lead is not grounded.

        Torque: 6.5 N*m (66 kgf*cm, 57 in.*lbf) 

      2. Clamp the starter in a vise.
      3. Connect the battery and an ammeter to the starter as shown.
      4. Check that the starter rotates smoothly and steadily while the pinion gear is moving out.

        Then measure the current.

        Standard current

        190 A or less at 11.5 V

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

        Fig 4: Connecting Field Coil Wire To Terminal C With Nut
        GTY288444Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSPECT STARTER ARMATURE ASSEMBLY 
    1. Inspect the resistance of the commutator.
      1. Measure the resistance between the segments of the commutator.

        Standard resistance

        Below 1 Ω

        If the result is not as specified, replace the armature assembly.

        Fig 5: Measuring Resistance Between Segments Of Commutator
        GTY288107Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Measure the resistance between the commutator and armature coil core.

        Standard resistance

        10 kΩ or higher

        If the result is not as specified, replace the armature assembly.

        Fig 6: Measuring Resistance Between Commutator And Armature Coil Core
        GTY288108Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Check the surface of the commutator for dirt or burns.

      If the surface is dirty or burnt, smooth it with 400-grit sandpaper or lathe it.

    3. Using a vernier caliper, measure the commutator diameter.

      Standard diameter

      35.0 mm (1.378 in.)

      Minimum diameter

      34.0 mm (1.339 in.)

      If the diameter is less than the minimum, replace the armature assembly.

      Fig 7: Measuring Commutator Diameter
      GTY177798Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a dial indicator, measure the commutator runout.

      Maximum commutator runout

      0.05 mm (0.0020 in.)

      If the commutator runout is more than the maximum, correct it using a lathe.

      Fig 8: Measuring Commutator Runout
      GTY175946Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Measure the undercut depth of the commutator.

      Standard undercut depth

      0.7 mm (0.028 in.)

      Minimum undercut depth

      0.2 mm (0.008 in.)

      If the undercut depth is less than the minimum, correct it with a hacksaw blade.

      Fig 9: Measuring Undercut Depth Of Commutator
      GTY189154Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSPECT STARTER YOKE ASSEMBLY 
    1. Inspect the resistance of the field coil.
      1. Measure the resistance between the lead wire and field coil brush lead.

        Standard resistance

        Below 1 Ω

        If the result is not as specified, repair or replace the yoke assembly.

        Fig 10: Inspecting Resistance Of Field Coil
        GTY193001Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Measure the resistance between the field coil end and field frame.

        Standard resistance

        10 kΩ or higher

        If the result is not as specified, repair or replace the yoke assembly.

        Fig 11: Measuring Resistance Between Brushes And Starter Yoke Body
        GTY193002Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSPECT BRUSH 
    1. Using a vernier caliper, measure the brush length.

      Standard length

      15.0 mm (0.590 in.)

      Minimum length

      9.0 mm (0.354 in.)

      If the brush length is less than the minimum, replace the brush holder and yoke assembly.

      Fig 12: Measuring Brush Length
      GTY258765Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSPECT STARTER BRUSH HOLDER ASSEMBLY 
    1. Inspect the insulation.
      1. Measure the resistance between the positive (+) and negative (-) brush holders.

        Standard resistance

        10 kΩ or higher

        If the result is not as specified, replace the brush holder assembly.

        Fig 13: Measuring Resistance Between Positive And Negative Brush Holders
        GTY287920Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Inspect the load of the brush spring.
      1. Take the pull scale reading immediately after the brush spring separates from the brush.

        Standard spring installed load

        21.5 to 27.5 N (2.2 to 2.8 kgf, 4.8 to 6.2 lbf)

        Minimum spring installed load

        12 N (1 kgf, 2.8 lbf)

        If the installed load is less than the minimum, replace the starter brush holder assembly.

        Fig 14: Inspecting Load Of Brush Spring
        GTY168664Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY 
    1. Check the gear teeth of the planetary gear and starter center bearing clutch for wear or damage.

      If any planetary gear is damaged, replace the planetary gear assembly. If any gear of the starter center bearing clutch is damaged, replace the starter center bearing clutch sub-assembly.

    2. Check the movement of the clutch pinion gear.
      1. Rotate the clutch pinion gear clockwise, and check that it turns freely.
      2. Try to rotate the clutch pinion gear counterclockwise, and check that it locks.

        If the clutch pinion gear cannot be turned clockwise smoothly, or does not lock in the counterclockwise direction, replace the starter center bearing clutch sub-assembly.

        Fig 15: Checking Movement Of Clutch Pinion Gear
        GTY169313Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSPECT STARTER MAGNETIC SWITCH ASSEMBLY 
    1. Inspect the resistance of the pull-in coil.
      1. Measure the resistance between terminals 50 and C.

        Standard resistance

        Below 1.0 Ω

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

        Fig 16: Inspecting Starter Magnetic Switch Assembly
        GTY287919Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Inspect the resistance of the hold-in coil.
      1. Measure the resistance between terminal 50 and the switch body.

        Standard resistance

        Below 2.0 Ω

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

        Fig 17: Measuring Resistance Between Terminal 50 And Switch Body
        GTY287918Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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