STARTER (for AWD): Inspection

INSPECT STARTER ASSEMBLY
NOTE: The following tests must be performed for no more than 5 seconds to prevent the coil from burning out.

Fig 1: Identifying Planetary Gears
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 2: Connecting Battery To Magnetic Switch
    Courtesy 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 3: Checking Pinion Gear Remains Out
    Courtesy 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 4: Inspecting Clutch Pinion Gear Return
    Courtesy 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 in the illustration.
  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 5: Connecting Field Coil Wire To Terminal C With Nut
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 6: Measuring Resistance Between Segments Of Commutator
    Courtesy 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.
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.
  
  Fig 7: Checking Surface Of Commutator For Dirt Or Burns
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 8: Measuring Commutator Diameter
  Courtesy 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 9: Measuring Commutator Runout
  Courtesy 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 10: Measuring Undercut Depth Of Commutator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 11: Measuring Resistance Between Terminal C And Brushes
    Courtesy 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 12: Measuring Resistance Between Brushes And Starter Yoke Body
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 13: Measuring Brush Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 14: Measuring Resistance Between Positive And Negative Brush Holders
    Courtesy 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 15: Inspecting Load Of Brush Spring
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 16: Checking Gear Teeth Of Planetary Gear And Starter Center Bearing Clutch For Wear
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 17: Inspecting Starter Magnetic Switch Assembly
    Courtesy 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 18: Measuring Resistance Between Terminal 50 And Switch Body
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002