2ZR-FE Starting: Starter: Inspection

INSPECT STARTER ASSEMBLY

NOTE: The following tests must be performed for no longer then 5 seconds to prevent the coil from burning out.

Perform the pull-in test.
1. Remove the nut and disconnect the lead wire from terminal C.
2. Connect the battery to the starter magnetic switch as shown in the illustration. Check that the clutch pinion gear moves outward. If the result is not as specified, replace the magnet starter switch assembly.
  
  Fig 1: Connecting Battery To Starter Magnetic Switch
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Perform the holding test.
1. Disconnect the negative (-) lead from terminal C. Check that the pinion gear remains out. If the result is not as specified, replace the magnet starter switch assembly.
  
  Fig 2: Checking Pinion Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Check the operation.
1. Disconnect the negative (-) lead from the switch body. Check that the clutch pinion gear returns in ward.
  If the result is not as specified, replace the magnet starter switch assembly.
  
  Fig 3: Checking Clutch Pinion Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Perform the no-load performance test.

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)
Clamp the starter in a vise.
Connect the battery and an ammeter to the starter as shown in the illustration.

Check that the starter rotates smoothly and steadily while the pinion gear is moving out. Check that the ammeter reads the specified current.

Standard current

STANDARD CURRENT SPECIFICATION

Tester connection	Condition	Specified condition
Positive battery terminal - Terminal 30 -Terminal 50	11.5 V	Below 90 A

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

Fig 4: Connecting Battery And Ammeter To Starter

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT STARTER ARMATURE ASSEMBLY

Inspect the commutator for open circuits.

Measure the resistance according to the value (s) in the table below.

Standard resistance

RESISTANCE REFERENCE

Tester connection	Specified condition
Segment - Segment	Below 1 Ω

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

Fig 5: Inspecting Commutator For Open Circuits

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Inspect the commutator for ground.

Measure the resistance according to the value (s) in the table below.

Standard resistance

RESISTANCE REFERENCE

Tester connection	Specified condition
Commutator - Armature core	10 kΩ or higher

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

Fig 6: Measuring Resistance According To Value

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Inspect the commutator surface for dirt and burns. If the surface is dirty or burnt, restore it with sandpaper (No. 400) or a lathe.
Using vernier calipers, measure the commutator length.
Standard length:

3.1 mm (0.122 in.)

Maximum length:

3.8 mm (0.150 in.)

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

Fig 7: Identifying Commutator Length
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY

Using vernier calipers, measure the brush length.
Standard length:

9.0 mm (0.354 in.)

Minimum length:

4.0 mm (0.158 in.)

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

Fig 8: Identifying Brush Length
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Inspect the brush holder.

Measure the resistance according to the value (s) in the table below.

Standard resistance

RESISTANCE REFERENCE

Tester connection	Specified condition
Positive (+) brush - Negative (-) brush	10 kΩ or higher

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

Fig 9: Measuring Resistance Value

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY
1. Inspect the gear teeth on the planetary gear, internal gear and starter clutch for wear and damage.
  If damaged, replace the starter planetary gear or starter center bearing clutch sub-assembly. Also check the starter planetary gear for wear or damage.
2. Inspect the starter clutch.
  1. Rotate the clutch pinion gear clockwise and check that it turns freely. Try to rotate the clutch pinion gear counterclockwise and check that it locks.
    If necessary, replace the starter center bearing clutch sub-assembly.
    
    Fig 10: Inspecting Starter Clutch
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT MAGNET SWITCH BODY

Inspect the plunger.
1. Push in the plunger and check that it returns quickly to its original position. If necessary, replace the magnet switch body.
  
  Fig 11: Inspecting Plunger
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Inspect the pull-in coil for open circuits.

Measure the resistance according to the value (s) in the table below.

Standard resistance

RESISTANCE REFERENCE

Tester connection	Specified condition
Terminal C - Terminal 50	Below 1 Ω

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

Fig 12: Measuring Resistance Value

Check whether the holding coil has an open circuit.

Measure the resistance according to the value (s) in the table below.

Standard resistance

RESISTANCE REFERENCE

Tester connection	Specified condition
Terminal 50 - Magnet switch body	Below 2 Ω

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

Fig 13: Checking Whether Holding Coil