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Starting System (1ZZ-FE/2ZZGE): Inspection

  1. INSPECT STARTER ASSY 
    NOTE: These tests must be performed within 3 to 5 seconds to prevent burnout of the coil.
    1. Perform the pull-in test.
      1. Remove the nut, then disconnect the lead wire from terminal C
        Fig 1: Disconnecting Lead Wire From Terminal C
        G02679427Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Connect the battery to the starter repair service kit as shown in the illustration. Check that the clutch pinion gear is extended.

        If the clutch pinion gear is not extended, replace the magnet switch.

        Fig 2: Connecting Battery To Starter Repair Service Kit
        G02679428Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Perform the hold-in test.
      1. Disconnect the negative (-) lead from terminal C. Check that the clutch pinion gear remains extended.

        If the clutch pinion gear returns, replace the magnet switch.

        Fig 3: Disconnecting Negative (-) Lead From Terminal C
        G02679429Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Check the operation.
      1. Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear returns.

        If the clutch pinion gear does not return, replace the magnet switch.

        Fig 4: Disconnecting Negative (-) Lead From Starter Body
        G02679430Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Perform the no-load performance test.
      1. Connect the lead 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) 

        Fig 5: Connecting Lead Wire To Terminal C With Nut
        G02679431Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Clamp the starter in a vise.
      3. Connect the battery and an ammeter to the starter as shown in the illustration.
      4. Check that the starter rotates smoothly and steadily with the clutch pinion gear extended. Check that the ammeter reads the specified current.

        Specified current: 90 A or less at 11.5 V 

        If the current is not as specified, replace the magnet switch.

      Fig 6: Connecting Battery And Ammeter To Starter
      G02679432Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSPECT STARTER RELAY ASSY 
    1. Check the starter relay resistance.
      1. Using an ohmmeter, measure the resistance between the terminals.
        STARTER RELAY ASSY TERMINALS RESISTANCE

        Tester Connection Specified Condition
        3-5 10kΩ or higher
        3-5 Below 1 Ω (Apply battery voltage to terminals 1 and 2)

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

      Fig 7: Measuring Resistance Between Starter Relay Assy Terminals
      G02679433Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSPECT IGNITION OR STARTER SWITCH ASSY 
    1. Measure the ignition starter switch resistance.
      IGNITION STARTER SWITCH TERMINALS RESISTANCE

      Switch Position Tester Connection Specified Condition
      LOCK - 10kΩ or higher
      ACC 1-3 Below 1 Ω
      ON 1 -2-3 5-6 Below 1 Ω
      START 1-2 4-5-6 Below 1 Ω

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

      Fig 8: Identifying Ignition Starter Switch Connectors And Switch Position
      G02679434Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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