Inspection [10/2017 - ]: Procedure

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INSPECT STARTER ASSEMBLY

WARNING:

As a large electric current passes through the cable during this inspection, a thick cable must be used.

If not, the cable may become hot and cause injury.

NOTE:

Perform each of the following tests within 3 to 5 seconds to prevent the coil from burning out.

Perform a pull-in test.

Remove the nut and disconnect the lead wire from terminal C.

Connect a battery to the magnetic switch as shown in the illustration. Check that the clutch pinion gear moves outward.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Starter Body
*b	Terminal 50
*c	Terminal C
	Moves Outward

If the clutch pinion gear does not move outward, replace the repair service starter kit.

Perform a hold-in test.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Terminal C
	Disconnect

While maintaining the battery connections of the pull-in test above, disconnect the negative (-) lead from terminal C. Check that the clutch pinion gear does not return inward.
If the clutch pinion gear returns inward, replace the repair service starter kit.

Perform a clutch pinion gear return test.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

	Disconnect
	Returns Inward

Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear returns inward.
If the clutch pinion gear does not return inward, replace the repair service starter kit.

Perform a no-load performance test.

Connect the lead 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)
Hold the starter assembly in a vise between aluminum plates.
NOTE:
Ensure that the starter assembly is secured in the vise to prevent it from falling out.

Connect the battery and an ammeter to the starter assembly as shown in the illustration.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Terminal 30
*b	Terminal 50
	Rotates

NOTE:

Do not allow any lead to get caught as the pinion gear operates.

Check that the starter operates smoothly and steadily while the pinion gear is moving outward.

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

Standard Current

Tester Connection	Condition	Specified Condition
Battery positive terminal - Terminal 30 - Terminal 50	11.5 V	90 A or less

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

INSPECT STARTER ARMATURE ASSEMBLY

HINT:

If there is no continuity between any segments, replace the starter armature assembly.

Check the commutator appearance.
If the surface is dirty or burnt, restore it with sandpaper (No. 400) or on a lathe.

Check the commutator for an open circuit.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Segment

Measure the resistance between the segments of the commutator.

Standard Resistance

Tester Connection	Condition	Specified Condition
Segment - Segment	Always	Below 1 Ω

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

Check the commutator for a short circuit.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Commutator
*b	Armature Coil Core

Measure the resistance between the commutator and armature coil core.

Standard Resistance

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

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

Using a vernier caliper, measure the commutator length.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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.

INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY

Using a vernier caliper, measure the brush length.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Length

Standard Length

9.0 mm (0.354 in.)

Minimum Length

4.0 mm (0.157 in.)

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

Check the brush insulation.

*a	Positive (+) Brush
*b	Negative (-) Brush

Measure the resistance between the positive (+) and negative (-) brushes.

Standard Resistance

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

If the result 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 gear, internal gear and starter clutch for wear or damage.
If damaged, replace the gear or clutch assembly. Also check the drive plate ring gear for wear or damage.

Rotate the pinion gear clockwise, and check that it turns freely. Try to rotate the pinion gear counterclockwise and check that it locks.

*a	Free
*b	Lock

If necessary, replace the starter drive housing assembly.

INSPECT REPAIR SERVICE STARTER KIT

Check the plunger.

Push in the plunger and check that it returns quickly to its original position.
If necessary, replace the repair service starter kit.

Check the pull-in coil for an open circuit.

*a	Terminal C
*b	Terminal 50

Measure the resistance between terminals 50 and C.

Standard Resistance

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

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

Check the hold-in coil for an open circuit.

*a	Magnet Switch Body
*b	Terminal 50

Measure the resistance between terminal 50 and the magnet switch body.

Standard Resistance

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

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