Section 8 (Starting System (2AZ-FE)): Starter: Inspection

WARNING: This page is about a different variant/trim than selected.

INSPECT STARTER ASSEMBLY

NOTE: Perform each of the following tests within 3 to 5 seconds.

Fig 1: Locating Planetary Gear

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Perform a pull-in test.
1. Disconnect the field coil lead wire from terminal C.
2. Connect the battery to the magnet starter switch as shown in the illustration and check that the pinion gear moves outward.
  If the clutch pinion gear does not move, replace the magnet starter switch assembly.
  
  Fig 2: Inspecting Starter Assembly (Pull-In Test)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Perform a hold-in test.
1. Check that the pinion gear does not return inward after the cable is disconnected from terminal C.
  If the clutch pinion gear returns inward, replace the magnet starter switch assembly.
  
  Fig 3: Inspecting Starter Assembly (Hold-In Test)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Inspect the clutch pinion gear return.
1. Disconnect the negative (-) lead from the switch body.
  Check that the pinion gear moves inward. If the clutch pinion gear does not return inward, replace the magnet starter switch assembly.

Perform an operation test without load.

Connect the field coil lead wire to terminal C.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
Clamp the starter in a vise.
Connect the battery and ammeter to the starter as shown in the illustration.

Fig 4: Checking Pinion Gear Movement
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Check that the starter rotates smoothly and steadily with the clutch pinion gear extended. Check that the ammeter indicates the specified current.

Standard Current

CURRENT SPECIFIED CONDITION

Tester Connection	Condition	Specified Condition
Battery positive terminal - Terminal 30 -Terminal 50	11.5 V	Below 90 A

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

Fig 5: Checking Starter Rotation

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INSPECT MAGNET STARTER SWITCH ASSEMBLY

Check the plunger.
1. Push in the plunger, then check that it returns quickly to its original position.
  If necessary, replace the magnet starter 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 SPECIFIED CONDITION

Tester Connection	Condition	Specified Condition
Terminal 50 - Terminal C	-	Below 1 Ω

Fig 7: Measuring Resistance Between Terminals 50 And C

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

Inspect the resistance of the hold-in coil.

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

Standard Resistance

RESISTANCE SPECIFIED CONDITION

Tester Connection	Condition	Specified Condition
Terminal 50 - Body ground	-	Below 2 Ω

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

Fig 8: Measuring Resistance Between Magnet Starter Switch Terminals 50 And Switch Body

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INSPECT STARTER ARMATURE ASSEMBLY

Inspect the resistance of the commutator.

Using an ohmmeter, measure the resistance between any 2 segments of the commutator.

Standard Resistance

RESISTANCE SPECIFIED CONDITION

Tester Connection	Condition	Specified Condition
Segment - Segment	-	Below 1 Ω

Fig 9: Measuring Resistance Between Segments Of Commutator

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

Check the commutator for a short to ground.

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

Standard Resistance

RESISTANCE SPECIFIED CONDITION

Tester Connection	Condition	Specified Condition
Commutator - Armature	-	10 kΩ or higher

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

Fig 10: Measuring Resistance Between Commutator And Armature Coil Core

Check the appearance.
If the surface is dirty or burnt, restore the surface with sandpaper (No. 400) or on a lathe.
Check the commutator circle for runout.
1. Place the commutator on V-blocks.
2. Using a dial indicator, measure the circle runout.
  Standard runout:
  
  0.02 mm (0.000787 in.)
  
  Maximum runout:
  
  0.05 mm (0.00197 in.)
  
  If the runout is greater than the maximum, replace the armature assembly.
  
  Fig 11: Measuring Commutator Circle Runout
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a vernier caliper, measure the commutator diameter.
Standard diameter:

29.0 mm (1.14 in.)

Minimum diameter:

28.0 mm (1.10 in.)

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

Fig 12: Measuring Commutator Diameter
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Check that the undercut portion is clean and free of foreign matter. Smooth out the edge.
Standard undercut depth:

0.7 mm (0.0276 in.)

Minimum undercut depth:

0.2 mm (0.00787 in.)

If the undercut depth is less than the minimum, increase the depth using a hacksaw blade.

Fig 13: Identifying Undercut Depth
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INSPECT STARTER BRUSH HOLDER ASSEMBLY

Release the claws of the springs, then remove the 4 brushes.
Using a vernier caliper, measure the brush length.
Standard length:

14.4 mm (0.567 in.)

Minimum length:

9.0 mm (0.354 in.)

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

Fig 14: Measuring Brush Length
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check the brush holder.

Using an ohmmeter, measure the resistance between the brushes.

Standard Resistance

RESISTANCE SPECIFIED CONDITION

Tester Connection	Condition	Specified Condition
A-B	-	10 kΩ or higher
A-C	-	10 kΩ or higher
A-D	-	Below 1 Ω
B-C	-	Below 1 Ω
B-D	-	10 kΩ or higher
C-D	-	10 kΩ or higher

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

Fig 15: Identifying Brushes

INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY
1. Inspect the gear teeth on the planetary gear, internal gear and starter clutch for wear or damage.
  If damaged, replace the gear or clutch assembly. Also check the planetary gears for wear or damage.
2. Inspect 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 center bearing clutch sub-assembly.
    
    Fig 16: Checking Clutch Pinion Gear Rotation
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002