Starting System: Starter: Inspection

INSPECT STARTER ASSEMBLY
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.
  2. Connect the battery to the starter magnetic switch. Check that the clutch pinion gear is extended.
    If the clutch pinion gear does not move, replace the magnet starter switch.
    
    Fig 1: Performing Pull-In Test
    Courtesy 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 is extended.
    If the clutch pinion gear returns inward, replace the starter magnet starter switch.
    
    Fig 2: Performing Hold-In Test
    Courtesy 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 inward, replace the magnet starter switch.
    
    Fig 3: Checking Operation
    Courtesy 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.
    Torque: 5.9 N*m (60 kgf*cm, 52 in.*lbf)
  2. Clamp the starter in a vise.
  3. Connect the battery and an ammeter to the starter.
  4. Check that the starter rotates smoothly and steadily while the pinion gear is moving outward. Then measure the current.
    Standard current:
    
    100A or less at 11.5V
    
    Fig 4: Performing No-Load Performance Test
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT STARTER ARMATURE ASSEMBLY
1. Check the commutator for an open circuit.
  1. Using an ohmmeter, measure the resistance between the segments of the commutator.
    Standard resistance:
    
    1 Ω or lower
    
    If the result is not as specified, replace the starter armature.
    
    Fig 5: Measuring Resistance Between Segments Of Commutator Using Ohmmeter
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the commutator for ground.
  1. Using an ohmmeter, 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 starter armature.
    
    Fig 6: Measuring Resistance Between Commutator & Armature Coil Core Using Ohmmeter
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Check whether the commutator surface is dirty or burnt.
  If necessary, smooth the surface with sandpaper (No. 400) or a lathe.
4. Check the commutator for runout.
  1. Place the commutator or V-blocks.
  2. Using a dial gauge, measure the runout.
    Maximum runout:
    
    0.05 mm (0.0020 in.)
    
    If the runout is greater than the maximum, correct it on a lathe.
    
    Fig 7: Checking Commutator For Runout
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using vernier calipers, 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 8: Measuring Commutator Diameter Using Vernier Calipers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Check that the undercut portion between the segments is free of foreign objects. Measure its depth.
  Standard undercut depth:
  
  0.7 mm (0.028 in.)
  
  Minimum undercut depth:
  
  0.2 mm (0.008 in.)
  
  If the under-cut depth is less than the minimum, correct it with hacksaw blade.
  
  Fig 9: Measuring Commutator Undercut Depth
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT STARTER YOKE ASSEMBLY
1. Check the starter yoke for an open circuit.
  1. Using an ohmmeter, measure the resistance between the lead wire and brushes.
    Standard resistance:
    
    1 Ω or lower
    
    If the result is not as specified, replace the starter yoke.
    
    Fig 10: Measuring Resistance Between Lead Wire & Brushes Using Ohmmeter
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the shunt coil for an open circuit.
  1. Using an ohmmeter, measure the resistance between shunt coil terminals A and B.
    Standard resistance:
    
    1.5 to 1.9 Ω at 20°C (68°F)
    
    If the result is not as specified, replace the starter yoke.
    
    Fig 11: Measuring Resistance Between Shunt Coil Terminals A & B Using Ohmmeter
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT BRUSH
1. Check the brush length.
  1. Using vernier calipers, measure the brush length.
    Standard length:
    
    15 mm (0.591 in)
    
    Minimum length:
    
    9.0 mm (0.354 in)
    
    If the length is less than the minimum, replace the brush holder and starter yoke.
    
    Fig 12: Measuring Brush Length Using Vernier Calipers
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT STARTER BRUSH HOLDER ASSEMBLY
1. Check the brush holder insulation.
  1. Using an ohmmeter, 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 (+) & Negative (-) Brush Holders Using Ohmmeter
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the brush spring load.
  1. Take the pull scale reading as soon as the brush spring separates from the brush.
    Standard spring load:
    
    21.5 to 27.5 N (2.2 to 2.8 kgf, 4.8 to 6.2 lbf)
    
    Minimum spring load:
    
    12.7 N (1.3 kgf, 2.9 lbf)
    
    If the spring load is less than the minimum, replace the brush spring.
    
    Fig 14: Identifying Brush Spring Load
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT STARTER CLUTCH SUB-ASSEMBLY
1. Check the clutch pinion gear.
  1. Hold the starter clutch, rotate the pinion gear clockwise and check that it turns freely.
  2. Try to rotate the pinion gear counterclockwise and check that it locks.
    If necessary, replace the starter clutch.
    
    Fig 15: Inspecting Starter Clutch Sub-Assembly
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT MAGNET STARTER SWITCH ASSEMBLY
1. Check the pull-in coil for an open circuit.
  1. Using an ohmmeter, measure the resistance between terminal 50 and C.
    Standard resistance:
    
    1 Ω or lower
    
    If the result is not as specified, replace the magnet starter switch.
    
    Fig 16: Measuring Resistance Between Terminal 50 & C Using Ohmmeter
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the holding coil for an open circuit.
  1. Using an ohmmeter, measure the resistance between terminals 50 and the switch body.
    Standard resistance:
    
    2 Ω or lower
    
    If the result is not as specified, replace the magnet starter switch.
    
    Fig 17: Measuring Resistance Between Switch Body & Terminal 50 Using Ohmmeter
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002