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Starting System: Inspection

  1. INSPECT STARTER ASSY 
    NOTE: These tests must be performed within 3 to 5 seconds to avoid burning out the coil.
    1. Do pull-in test
      1. Disconnect the field coil lead from terminal C.
      2. Connect the battery to the magnetic switch as shown. Check that the clutch pinion gear is extended.
      Fig 1: Disconnecting Field Coil Lead From Terminal C
      G03062584Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If the clutch pinion gear does not move, replace the magnetic switch.

    2. Do hold-in test
      1. Disconnect the negative (-) lead from the terminal C with the above condition (a) is being maintained. Check that the pinion gear remains extended.

      If the clutch pinion gear returns inward, replace the magnetic switch.

      Fig 2: Disconnecting Negative (-) Lead From Terminal C
      G03062585Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Inspect clutch pinion gear return
      1. Disconnect the negative (-) lead from the switch body. Check that the clutch pinion gear returns.

      If the clutch pinion gear does not return, replace the magnetic switch.

      Fig 3: Disconnecting Negative (-) Lead From Switch Body
      G03062586Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Do no-load performance test
      1. Connect the field coil 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.
        Fig 4: Connecting Battery And Ammeter To Starter
        G03062587Courtesy 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 11.5 V 

  2. INSPECT STARTER RELAY ASSY 
    1. Continuity inspection.
      1. Using an ohmmeter, check for continuity between each terminal.

      Specified condition 

      STARTER RELAY TERMINALS CONTINUITY

      Terminal No. Specified condition
      1 - 2 Continuity
      3 - 5 No continuity
      3 - 5 Continuity (Applying battery voltage terminals 1 and 2)
      Fig 5: Checking Continuity Between Starter Relay Terminals
      G03062588Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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