Section 5 (Starting System (2ZR-FE)): Starter: Inspection
- INSPECT STARTER ASSEMBLY NOTE: Perform each of the following tests within 3 to 5 seconds.
- Perform a pull-in test.
- Disconnect the field coil lead wire from terminal C.
- Connect the battery to the magnet starter switch as shown in the illustration and check that the pinion gear moves outward. If the clutch pinion gear does not move, replace the magnet switch assembly.
- Perform a hold-in test.
- Check that the pinion gear does not return inward after the cable is disconnected from terminal C.
If the clutch pinion gear returns inward, replace the magnet starter switch assembly.
- Check that the pinion gear does not return inward after the cable is disconnected from terminal C.
- Inspect the clutch pinion gear return.
- Disconnect the negative (-) lead from the switch body.
Check that the pinion gear moves inward. If the clutch pinion gear does not return inward, replace the magnet starter switch assembly.
- Disconnect the negative (-) lead from the switch body.
- Perform an operation test without load.
- Connect the lead wire to terminal C.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
- Clamp the starter in a vise.
- Connect the battery and ammeter to the starter as shown in the illustration.
- Check that the starter rotates smoothly and steadily with the clutch pinion gear extended. Check that the ammeter indicates the specified current.
Standard Current
CURRENT SPECIFIED CONDITIONTester Connection Condition Specified Condition Buttery positive terminal - Terminal 30 - Terminal 50 11.5 V Below 90 A
- Connect the lead wire to terminal C.
- Perform a pull-in test.
- INSPECT MAGNET STARTER SWITCH ASSEMBLY
- Check the plunger.
- Push in the plunger, then check that it returns quickly to its original position.
If necessary, replace the magnet starter switch assembly.
- Push in the plunger, then check that it returns quickly to its original position.
- Inspect the resistance of the pull-in coil.
- Using an ohmmeter, measure the resistance between terminals 50 and C.
Standard Resistance
RESISTANCE SPECIFIED CONDITIONTester Connection Condition Specified Condition Terminal 50 - Terminal C - Below 1 Ω Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
If the result is not as specified, replace the magnet starter switch assembly.
- Using an ohmmeter, measure the resistance between terminals 50 and C.
- Inspect the resistance of the hold-in coil.
- Check the plunger.
- INSPECT STARTER ARMATURE ASSEMBLY
- Inspect the resistance of the commutator.
- Check the commutator for a short to ground.
- Using an ohmmeter, measure the resistance between the commutator and the armature coil core.
Standard Resistance
RESISTANCE SPECIFIED CONDITIONTester Connection Condition Specified Condition Commutator - Armature - 10 kΩ or higher Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
If the result is not as specified, replace the starter armature assembly.
- Using an ohmmeter, measure the resistance between the commutator and the armature coil core.
- Check the appearance.
- If the surface is dirty or burnt, restore the surface with sandpaper (No. 400) or on a lathe.
- Check the commutator circuit for runout.
- Place the commutator on V-blocks.
- Using a dial indicator, measure the circle runout.
Standard runout:
0.02 mm (0.000787 in.)
Maximum runout:
0.05 mm (0.00197 in.)
If the runout is greater than the maximum, replace the armature assembly.
- Using a vernier caliper, measure the commutator diameter.
Standard diameter:
29 mm (1.14 in.)
Minimum diameter:
28 mm (1.10 in.)
If the diameter is less than the minimum, replace the armature.
- Check that the undercut portion is clean and free of foreign matter. Smooth out the edge.
Standard undercut depth:
0.7 mm (0.0276 in.)
Minimum undercut depth:
0.2 mm (0.00787 in.)
If the undercut depth is less than the minimum, increase the depth using a hacksaw blade.
- INSPECT STARTER BRUSH HOLDER ASSEMBLY
- Release the claws of the springs, then remove the 4 brushes.
- Using a vernier caliper, measure the brush length.
Standard length:
14.4 mm (0.567 in.)
Minimum length:
9.0 mm (0.354 in.)
If the length is less than the minimum, replace the starter brush holder assembly.
- Check the brush holder.
- Using an ohmmeter, measure the resistance between the brushes.
Standard Resistance
RESISTANCE SPECIFIED CONDITIONTester Connection Condition Specified Condition A-B - 10 kΩ or higher A-C - 10 kΩ or higher A-D - Below 1 Ω B-C - Below 1 Ω B-D - 10 kΩ or higher C-D - 10 kΩ or higher If the result is not as specified, replace the starter brush holder assembly.
- Using an ohmmeter, measure the resistance between the brushes.
- INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY
- Inspect the gear teeth on the planetary gear, internal gear and starter clutch for wear or damage. If damaged, replace the gear or clutch assembly. Also check the planetary gears for wear or damage.
- Inspect the starter clutch.
- 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.
- 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.