Starting System: Starter: Inspection

INSPECT STARTER ARMATURE ASSEMBLY
1. Measure the resistance.
  1. Measure the resistance between the segments of the commutator.
    Standard resistance: Below 1 Ω
    
    If the result is not as specified, replace the starter armature assembly.
    
    Fig 1: Measuring Resistance Between Segments Of Commutator
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Measure the resistance between a segment of the commutator and armature coil core.
    Standard resistance: 10 kΩ or higher
    
    If the result is not as specified, replace the armature assembly.
    
    Fig 2: Measuring Resistance Between Segments Of Commutator & Armature Coil Core
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Inspect circle runout.
  1. Place the armature on V-blocks.
  2. Using a dial gauge, measure the circle runout.
    Maximum circle runout: 0.05 mm (0.0020 in.)
    
    If the circle runout is greater than the maximum, correct it on a lathe.
    
    Fig 3: Inspecting Circle Runout
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a vernier caliper, measure the commutator diameter.
  - Standard undercut depth: 35.0 mm (1.378 in.)
  - Minimum undercut depth: 34.0 mm (1.339 in.)
  If the diameter is less than the minimum, replace the armature assembly.
  
  Fig 4: Measuring Commutator Diameter Using Vernier Caliper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. 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 5: Measuring Undercut Depth Of Commutator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Inspect the bearings.
  1. Check that the bearing rotate smoothly.
    If the diameter is less than the minimum, replace the armature assembly.
INSPECT STARTER YOKE ASSEMBLY
1. Inspect the field coil for an open circuit.
  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, replace the starter yoke assembly.
    
    Fig 6: Measuring Resistance Between Lead Wire And Field Coil Brush Lead
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Inspect the shunt coil for an open circuit.
  1. Measure the resistance between the shunt coil terminals.
    Standard resistance: 1.5 to 1.9 Ω at 20°C (68°F)
    
    If the result is not as specified, replace the starter yoke assembly.
    
    Fig 7: Measuring Resistance Between Shunt Coil Terminals
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT BRUSH
1. Using a vernier caliper, measure the brush length.
  - Standard length: 15.0 mm (0.591 in.)
  - Minimum length: 9.0 mm (0.354 in.)
  If the length is less than the minimum, replace the starter brush holder assembly and starter yoke assembly.
  
  Fig 8: Measuring Brush Length Using Vernier Caliper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT STARTER BRUSH HOLDER ASSEMBLY
1. Inspect the brush insulation.
  1. Using an ohmmeter, 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 9: Measuring Resistance Between Positive & Negative Brush Holders
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Take the pull scale reading the instant the brush spring separates from the brush.
  - Standard spring installed load: 21.5 to 27.5 N (2.2 to 2.8 kgf*cm, 4.8 to 6.2 in.*lbf)
  - Minimum spring installed load: 12.7 (1.3 kgf*cm, 2.9 in.*lbf)
  If the spring load is less than the minimum, replace the brush spring.
  
  Fig 10: Pulling Scale Reading
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT STARTER CLUTCH SUB-ASSEMBLY
1. Rotate the pinion gear clockwise, and check that it turns freely. Try to rotate the pinion gear counterclockwise and check that it locks. If necessary, replace the clutch.
  
  Fig 11: Inspecting Starter Clutch Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT MAGNET STARTER SWITCH ASSEMBLY
1. Check if the pull-in coil has an open circuit.
  1. Measure the resistance between terminals 50 and C.
    Standard resistance: Below 2 Ω
    
    If the result is not as specified, replace the magnet starter switch assembly.
    
    Fig 12: Measuring Resistance Between Terminals 50 & C
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check if the hold-in coil has an open circuit.
  1. Measure the resistance between terminal 50 and the switch body.
    Standard resistance: Below 1 Ω
    
    If the result is not as specified, replace the magnet starter switch assembly.
    
    Fig 13: Measuring Resistance Between Terminal 50 & Switch Body
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002