Starting System (1GR-FE): Inspection

INSPECT STARTER ASSY
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 as shown in the illustration. Check that the clutch pinion gear is extended.
    If the clutch pinion gear does not move, replace the magnet starter switch.
    
    Fig 1: Connecting Battery To Starter Magnetic Switch
    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: Disconnecting Negative Lead From Terminal C
    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: Disconnecting Negative Lead From Starter Body
    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 as shown in the illustration.
    
    Fig 4: Connecting Battery And An Ammeter To Starter
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Check that the starter rotates smoothly and steadily with the clutch pinion gear extended. Check that the ammeter reads the specified current.
    Standard: 100 A or less at 11.5 V
    
    If the result is not as specified, replace the starter.

INSPECT STARTER RELAY ASSY

Check the resistance.

Using an ohmmeter, measure the resistance between the terminals.

TESTER CONNECTION SPECIFIED CONDITION CHART

Tester Connection	Specified Condition
3-5	10 k or higher
3-5	Below 1Ω (Apply battery voltage to terminals 1 and 2)

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

Fig 5: Measuring Resistance Between Terminals

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT IGNITION OR STARTER SWITCH ASSY

Check the resistance.

Using an ohmmeter, measure the resistance between the terminals.

Standard:

TESTER CONNECTION SPECIFIED CONDITION CHART

Switch Condition	Tester Connection	Specified Condition
LOCK	-	10k or higher
ACC	1 (AM1)-3(ACC)	Below 1Ω
ON	1 (AM1)-3(ACC)-4(IG1) 7 (IG2) - 8 (AM2)	Below 1Ω
START	1 (AM1)-2(ST1)-4(1G1) 6 (ST2) - 7 (IG2) - 8 (AM2)	Below 1Ω

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

Fig 6: Measuring Resistance Between Terminals