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Starting System & Charging System: Inspection

  1. INSPECT STARTER ASSY 
    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 on the left. Check that the clutch pinion gear extends.

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

        Fig 1: Connecting Battery To Magnetic Switch
        G02972348Courtesy 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: Disconnecting Negative (-) Lead From Terminal C
        G02972349Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Check the clutch pinion gear return.
      1. Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear returns.

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

        Fig 3: Disconnecting Negative (-) Lead From Starter Body
        G02972350Courtesy 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 

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

        Fig 4: Connecting Battery & An Ammeter To Starter
        G02972351Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSPECT IGNITION OR STARTER SWITCH ASSY (W/O SMART KEY SYSTEM) 
    1. Measure the switch resistance.

      Standard: 

      Fig 5: Switch Condition - Tester Condition Specification Table
      G02972352Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If the result is not as specified, replace the ignition or starter switch assy.

      Fig 6: Inspecting Ignition Or Starter Switch Assy (W/O Smart Key System)
      G02972353Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. ENGINE SWITCH (w/SMART KEY SYSTEM) 
    1. Using an ohmmeter, measure the engine switch resistance.

      Standard: 

      Fig 7: Identifying Engine Switch Connector Terminal
      G02972354Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      ENGINE SWITCH - TESTER CONNECTION SPECIFICATIONS

      Engine switch Operation Tester Connection Specified Condition
      OFF 7 (SS1) - 5 (GND) 10 kΩ or higher
      OFF 2 (SS2) - 5 (GND) 10 kΩ or higher
      ON 7(SS1) -5 (GND) Below 1 Ω
      ON 2 (SS2) - 5 (GND) Below 1 Ω

      If the result is not as specified, replace the switch assy.

  4. INSPECT RELAY (Marking: STARTER) 
    1. Check the resistance.
      1. Using an ohmmeter, measure the resistance between the terminals.

      Standard: 

      TESTER CONNECTION - SPECIFIED CONDITION

      Tester Connection Specified Condition
      3 - 5 10 kΩ or higher
      3 - 5 Below 1 Ω (when battery voltage is applied between terminals 1 and 2)

      If the result is not as specified, replace the relay.

      Fig 8: Measuring Resistance Between Terminals Using An Ohmmeter
      G02972355Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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