Starting System: Starter: Inspection

INSPECT STARTER ASSEMBLY
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. Check that the clutch pinion gear extends.
    If the clutch pinion gear does not move, replace the magnetic switch.
  Fig 1: Inspecting Starter Assembly (Pull-In Test)
  Courtesy 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: Inspecting Starter Assembly (Hold-In Test)
  Courtesy 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: Inspecting Starter Assembly (Clutch Pinion Gear Return)
  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.
  2. Clamp the starter in a vise.
  3. Connect the battery and an ammeter to the starter as shown in the illustration.
    
    Fig 4: Inspecting Starter Assembly (No-Load Performance)
    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.
    Specified current:
    
    90 A or less at 11.5V
    
    If the result is not as specified, replace the starter assembly.
INSPECT REPAIR SERVICE STARTER KIT
1. Check the plunger.
  1. Push in the plunger and check that it returns quickly to its original position.
    If necessary, replace the repair service starter kit.
  Fig 5: Checking Plunger
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the resistance.
  1. Using an ohmmeter, measure the resistance between terminals 50 and C.
    Resistance:
    
    below 1 Ω
    
    If the result is not as specified, replace the repair service starter kit.
  Fig 6: Measuring Resistance Between Terminals 50 And C
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using an ohmmeter, measure the resistance between terminal 50 and the starter kit body.
  Resistance:
  
  below 2 Ω
  
  If the result is not as specified, replace the repair service starter kit.
Fig 7: Measuring Resistance Between Terminal 50 And Starter Kit Body
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT STARTER ARMATURE ASSEMBLY
1. Check the resistance.
  1. Using an ohmmeter, measure the resistance between the segments of the commutator.
    Resistance:
    
    below 1 Ω
    
    If the result is not as specified, replace the starter armature.
  Fig 8: Measuring Resistance Between Segments Of Commutator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using an ohmmeter, measure the resistance between the segment of the commutator and armature coil core.
  Resistance:
  
  10 kΩ or higher
  
  If the result is not as specified, replace the starter armature.
  
  Fig 9: Measuring Resistance Between Segment Of Commutator And Armature Coil Core
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Check the commutator surface for dirt or burning.
  If the surface is dirty or burnt, smooth the surface with 400-grit sandpaper or leather.
4. Check the commutator depth.
  1. Using vernier calipers, measure the commutator depth.
    Standard depth:
    
    3.1 mm (0.122 in.)
    
    Maximum depth:
    
    3.8 mm (0.150 in.)
    
    If the length is greater than the maximum, replace the starter armature assembly.
Fig 10: Measuring Commutator Depth
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY
1. Check the brush length.
  1. 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 minimum, replace the starter commutator end frame.
  Fig 11: Measuring Brush Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the resistance.
  1. Using an ohmmeter, measure the resistance between the positive (+) and negative (-) brushes.
    Resistance:
    
    10 kΩ or higher
    
    If the resistance is not as specified, repair or replace the starter commutator end frame.
    
    Fig 12: Measuring Resistance Between Positive (+) And Negative (-) Brushes
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT MOTOR TERMINAL STARTER KIT
1. Check the starter clutch.
  1. Rotate the clutch pinion gear counterclockwise and check that it turns freely. Try to rotate the clutch pinion gear clockwise. Check that it locks.
    If necessary, replace the motor terminal starter kit.
    
    Fig 13: Checking Clutch Pinion Gear
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002