Engine Mechanical: Starter: Starting: Starter: Inspection

INSPECT STARTER ASSEMBLY
NOTE: The following tests must be performed for no more than 5 seconds to prevent the coil from burning out.

Fig 1: Identifying Planetary Gears
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Perform pull-in test.
  1. Disconnect the lead wire from terminal C.
  2. Connect the battery to the magnet starter switch as shown in the illustration. Check that the clutch pinion gear moves outward.
    If the clutch pinion gear does not move outward, replace the magnet starter switch assembly.
    
    Fig 2: Inspecting Starter Assembly (Pull-In Test)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Perform holding test.
  1. Disconnect the negative (-) terminal lead from terminal C with the condition specified in the pull-in test above being maintained. Check that the pinion gear remains out. If the clutch pinion gear moves inward, replace the magnet starter switch assembly.
    
    Fig 3: Inspecting Starter Assembly (Holding Test)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Inspect clutch pinion gear return.
  1. Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear moves inward.
    If the clutch pinion gear does not move inward, replace the magnet starter switch assembly.
    
    Fig 4: Inspecting Clutch Pinion Gear Return
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Perform the operation test without load.
  1. Connect the field coil wire to terminal C with the nut. Make sure that the lead is not grounded.
    Torque: 6.5 N*m (66 kgf*cm, 57 in.*lbf)
  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 while the pinion gear is moving out. Then measure the current.
    Standard current:
    
    190 A or less at 11.5 V
    
    If the result is not as specified, replace the starter assembly.
    
    Fig 5: Performing Operation Test Without Load
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT STARTER ARMATURE ASSEMBLY

Inspect the commutator for an open circuit.

Measure the resistance according to the value(s) in the table below.

Standard Resistance

RESISTANCE SPECIFICATION

Tester Connection	Condition	Specified Condition
Commutator	Always	Below 1 Ω

If the result is not as specified, replace the starter armature assembly.

Fig 6: Inspecting Commutator For An Open Circuit

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Inspect the commutator for a short circuit.

Measure the resistance according to the value(s) in the table below.

Standard Resistance

RESISTANCE SPECIFICATION

Tester Connection	Condition	Specified Condition
Commutator - Armature coil core	Always	10 kΩ or higher

If the result is not as specified, replace the starter armature assembly.

Fig 7: Inspecting Commutator For Short Circuit

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check the surface of the commutator for dirt and burns.
If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe.
Using a vernier caliper, measure the commutator diameter.
Standard diameter:

35.0 mm (1.38 in.)

Minimum diameter:

34.0 mm (1.34 in.)

If the diameter is less than the minimum, replace the starter armature assembly.

Fig 8: Measuring Commutator Diameter
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a dial indicator, measure the commutator runout.
Maximum commutator runout:

0.05 mm (0.00197 in.)

If the commutator runout is more than the maximum, correct it using a lathe.

Fig 9: Measuring Commutator Runout
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Measure the undercut depth of the commutator.
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.

Fig 10: Identifying Undercut Depth Of Commutator
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:
  
  10.0 mm (0.394 in.)
  
  If the brush length is less than the minimum, replace the starter brush holder assembly and yoke assembly.
  
  Fig 11: Measuring Brush Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT STARTER BRUSH HOLDER ASSEMBLY

Inspect the insulation.

Measure the resistance according to the value(s) in the table below.

Standard Resistance

RESISTANCE SPECIFICATION

Tester Connection	Condition	Specified Condition
Positive {+) brush holder - Negative (-) brush holder	Always	10 kΩ or higher

If the result is not as specified, replace the starter brush holder assembly.

Fig 12: Inspecting Starter Brush Holder Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Inspect the load of the brush spring.
1. Take a pull scale reading immediately after the brush spring separates from the brush.
  Standard spring installed load:
  
  21.5 to 27.5 N (2.2 to 2.8 kgf, 4.8 to 6.2 lbf)
  
  Minimum spring installed load:
  
  12.3 N (1.3 kgf, 2.8 lbf)
  
  If the installed load is less than the minimum, replace the starter brush holder assembly.
  
  Fig 13: Inspecting Load Of Brush Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT STARTER YOKE ASSEMBLY

Inspect the resistance of the field coil.

Measure the resistance according to the value(s) in the table below.

Standard Resistance

RESISTANCE SPECIFICATION

Tester Connection	Condition	Specified Condition
Terminal C wire - Brushes	Always	Below 1 Ω

If the result is not as specified, repair or replace the starter yoke assembly.

Fig 14: Inspecting Resistance Of Field Coil

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Measure the resistance according to the value(s) in the table below.

Standard Resistance

RESISTANCE SPECIFICATION

Tester Connection	Condition	Specified Condition
Brushes - Starter yoke body	Always	10 kΩ or higher

If the result is not as specified, repair or replace the starter yoke assembly.

Fig 15: Measuring Resistance Between Brushes And Starter Yoke Body

INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY
1. Check the gear teeth of the planetary gear and starter center bearing clutch for wear or damage. If any planetary gear is damaged, replace the planetary gear assembly. If any gear of the starter center bearing clutch is damaged, replace the starter center bearing clutch sub-assembly.
2. Check the movement of the clutch pinion gear.
  1. Rotate the clutch pinion gear clockwise, and check that it turns freely.
  2. Try to rotate the clutch pinion gear counterclockwise, and check that it locks. If the clutch pinion gear cannot be turned clockwise smoothly, or does not lock in the counterclockwise direction, replace the starter center bearing clutch sub-assembly.
    
    Fig 16: Checking Movement Of Clutch Pinion Gear
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT MAGNET STARTER SWITCH ASSEMBLY

Inspect the pull-in coil.

Measure the resistance according to the value(s) in the table below.

Standard Resistance

RESISTANCE SPECIFICATION

Tester Connection	Condition	Specified Condition
Terminal 50 - Terminal C	Always	Below 1 Ω

If the result is not as specified, replace the magnet starter switch assembly.

Fig 17: Measuring Resistance Between Terminal 50 And Terminal C

Inspect the holding coil.

Measure the resistance according to the value(s) in the table below.

Standard Resistance

RESISTANCE SPECIFICATION

Tester Connection	Condition	Specified Condition
Terminal 50 - Switch body	Always	Below 2 Ω

If the result is not as specified, replace the magnet starter switch assembly.

Fig 18: Measuring Resistance Between Terminal 50 And Switch Body