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Starting System: Starter: Inspection

  1. INSPECT STARTER ASSEMBLY 
    NOTE: These tests must be performed within 3 to 5 seconds to avoid burning out the coil.
    1. Perform the pull-in test.
      1. Disconnect the lead wire from terminal C.
      2. Connect the battery to the magnetic switch as shown in the illustration. Check that the clutch pinion gear extends.

        If the clutch pinion gear does not move, replace the magnetic switch.

        Fig 1: Inspecting Starter Assembly (Pull-In Test)
        G05140037Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Perform the hold-in test.
      1. Maintain the battery connections in step (a), but disconnect the negative (-) lead from terminal C. Check that the pinion gear remains extended.

        If the clutch pinion gear returns inward, replace the magnetic switch.

        Fig 2: Inspecting Starter Assembly (Hold-In Test)
        G05140038Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Check the clutch pinion gear return.
      1. Disconnect the negative (-) lead from the switch body. Check that the clutch pinion gear returns.

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

        Fig 3: Checking Clutch Pinion Gear Return
        G05134778Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Perform the no-load performance test.
      1. Connect the lead wire to terminal C. Make sure that the lead is not grounded.
      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 

        Fig 4: Inspecting Starter Assembly (No-Load Performance Test)
        G05129689Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSPECT REPAIR SERVICE STARTER KIT 
    1. Check the plunger.
      1. Push in the plunger and check that it returns quickly to its original position.

        If necessary, replace the repair service starter kit.

        Fig 5: Checking Plunger
        G04962995Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Check if the pull-in coil has an open circuit.
      1. Measure the resistance between terminals 50 and C.

        Resistance: Below 1 Ω 

        If the result is not as specified, replace the repair service starter kit.

        Fig 6: Measuring Resistance Between Terminals 50 And C
        G05140042Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Check if the hold-in coil has an open circuit.
      1. Measure the resistance between terminal 50 and the switch body.

        Resistance: Below 2 Ω 

        If the result is not as specified, replace the repair service starter kit.

        Fig 7: Measuring Resistance Between Terminal 50 And Switch Body
        G05140043Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSPECT STARTER ARMATURE ASSEMBLY 
    1. Measure if the commutator has an open circuit.
      1. Check the resistance between the segments of the commutator.

        Resistance: Below 1 Ω 

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

        Fig 8: Checking Resistance Between Segments Of Commutator
        G05140044Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Check if the commutator is grounded.
      1. Measure the resistance between the commutator and armature coil core.

        Resistance: 10 kΩ or higher 

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

        Fig 9: Measuring Resistance Between Commutator And Armature Coil Core
        G05140045Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Check the commutator for contamination and burns on its surface.

      If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe.

    4. Using a vernier caliper, measure the commutator's length.

      Standard length: 3.3 to 4.0 mm (0.1299 to 0.1575 in.) 

      If the length is greater than the maximum, replace the starter armature.

      Fig 10: Identifying Commutator's Length
      G05134785Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY 
    1. Using a vernier caliper, measure the brush length.

      Specified length: 4.0 to 9.0 mm (0.158 to 0.354 in.) 

      If the length is less than the minimum, replace the starter commutator end frame.

      Fig 11: Identifying Brush Length
      G05134786Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Check the brush insulation.
      1. Measure the resistance between the positive (+) and negative (-) brush.

        Resistance: 10 kΩ or higher 

        If the result is not as specified, repair or replace starter commutator end frame.

        Fig 12: Measuring Resistance Between Positive (+) And Negative (-) Brush
        G05140048Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSPECT REPAIR SERVICE STARTER KIT 
    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 service starter kit.

        Fig 13: Rotating Clutch Pinion Gear
        G05134788Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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