Section 4 (Starting (2GR-FSE)): Starter: Inspection

WARNING: This page is about a different car, the 2006 Lexus IS 350. However, it is still accessible from the selected car via links, so may be relevant.

INSPECT STARTER ASSEMBLY

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

Perform pull-in test:
1. Disconnect the wire from terminal C.
2. Connect the battery to the magnetic 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 repair service starter kit.
  
  Fig 1: Inspecting Starter (Perform Pull-In Test)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Perform hold-in test:
1. Disconnect the negative (-) terminal lead from terminal C under condition pull-in test. Check that the pinion gear remains out. If the clutch pinion gear moves inward, replace the repair service starter kit.
  
  Fig 2: Inspecting Starter (Perform Hold-In Test)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 repair service starter kit.
Perform no-load performance test:

Fig 3: Inspecting Starter (Clutch Pinion Gear Return)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Connect the wire to terminal C with the nut. Make sure that the lead is not grounded.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
Clamp the starter in a vise.
Connect the battery and an ammeter to the starter as shown in the illustration.

Check that the starter rotates smoothly and steadily with the clutch pinion gear remaining out. Check that the ammeter reads the specified current.

Specified current

CONDITION SPECIFIED CONDITION CHART

Condition	Specified condition
at 11.5 V	90 A or less

If the current is not as specified, oveRHaul the starter.

Fig 4: Inspecting Starter (Perform No-Load Performance Test)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT STARTER ARMATURE ASSEMBLY

Inspect the resistance of the commutator.

Using an ohmmeter, measure the resistance between the segments of the commutator.

Standard resistance

TESTER CONNECTION SPECIFIED CONDITION CHART

Tester connection	Specified condition
Segment - Segment	Below 1 Ω

Fig 5: Measuring Resistance Between Segments Of Commutator

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If the resistance is not as specified, replace the armature assembly.

Using an ohmmeter, measure the resistance between the commutator and armature coil core.

Standard resistance

TESTER CONNECTION SPECIFIED CONDITION CHART

Tester connection	Specified condition
Commutator - Armature	10 kΩ or higher

If the resistance is not as specified, replace the armature assembly.

Fig 6: Measuring Resistance Between Commutator And Armature Coil Core

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check the surface of the commutator for dirt or burn.
If the surface is dirty or burnt, smooth it with 400-grit sandpaper or trim it on a lathe.
Using vernier calipers, measure the commutator length.
Standard length: 3.1 mm (0.122 in.)

Maximum length: 3.8 mm (0.150 in.)

If the length is greater than the maximum, replace the starter armature assembly.

Fig 7: Identifying Commutator Length
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY

Using vernier calipers, measure the brush length.
Standard length: 9.0 mm (0.354 in.)

Minimum length: 4.0 mm (0.158 in.)

Fig 8: Identifying Brush Length
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If the length is less than the minimum, replace the starter commutator end frame assembly.

Using an ohmmeter, measure the resistance between the positive (+) and negative (-) brushes.

Standard resistance

TESTER CONNECTION SPECIFIED CONDITION CHART

Tester connection	Specified condition
Positive (+) brush - Negative (-) brush	10 kΩ or higher

Fig 9: Measuring Resistance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If the resistance is not as specified, replace the starter commutator end frame assembly.

INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY

Check the gear teeth on the planetary gears, internal gear and starter clutch for wear or damage. If any of the gears is damaged, replace the center bearing clutch sub-assembly.
Check the starter clutch pinion gear.
1. Turn the clutch pinion gear clockwise and check that it turns freely. Try to turn the clutch pinion gear counterclockwise and check that it locks.
  
  Fig 10: Turning Clutch Pinion Gear Clockwise And Freely
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If necessary, replace the center bearing clutch sub-assembly.

INSPECT REPAIR SERVICE STARTER KIT

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 11: Checking Plunger
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using an ohmmeter, measure the resistance between terminals 50 and C.

Standard resistance

TESTER CONNECTION SPECIFIED CONDITION CHART

Tester connection	Specified condition
Terminal 50 - Terminal C	Below 1 Ω

If the result is not as specified, replace the repair service starter kit.

Fig 12: Measuring Resistance Between Terminals

Using an ohmmeter, measure the resistance between terminal 50 and the switch body.

Standard resistance

TESTER CONNECTION SPECIFIED CONDITION CHART

Tester connection	Specified condition
Terminal 50 - Switch body	Below 2 Ω

If the result is not as specified, replace the repair service starter kit.

Fig 13: Measuring Resistance Between Terminal And Switch Body