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Inspection [09/2014 - 11/2017]: Procedure

WARNING: This page is about a different car, the 2017 Lexus RC 350, 2017 Lexus RC 300, 2016 Lexus RC 350, 2016 Lexus RC 300, and 2015 Lexus RC 350. However, it is still accessible from the selected car via links, so may be relevant.
  1. 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.

    1. Perform a pull-in test.
      1. Remove the nut, and disconnect the field coil lead wire from terminal C.
      2. Connect a battery to the magnet switch as shown in the illustration. Check that the clutch pinion gear moves outward.
        GTY508069Courtesy 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.

    2. Perform a hold-in test.
      GTY503079Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Starter Body
      *b Terminal 50
      *c Terminal C
      Disconnect
      1. While maintaining the battery connections of the pull-in test, 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.

    3. Perform a return test.
      GTY518041Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Starter Body
      *b Terminal 50
      *c Terminal C
      Disconnect
      Returns inward
      1. 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.

    4. Perform a no-load performance test.
      1. Connect the field coil lead wire to terminal C with the nut. Make sure that the field coil lead wire is not grounded.

        Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

      2. Secure 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.

      3. Connect the battery and an ammeter to the starter assembly as shown in the illustration.
        GTY503302Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Terminal 30
        *b Terminal 50
        *c Starter Body
        Rotates
        NOTE:

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

      4. Check that the starter assembly operates smoothly and steadily while the clutch 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 Below 90 A

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

  2. INSPECT STARTER ARMATURE ASSEMBLY 

    HINT: 

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

    1. Check the commutator appearance.

      If the surface is dirty or burnt, restore it with sandpaper (400-grit) or on a lathe.

    2. Check the commutator for an open circuit.
      GTY470023Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Segment
      1. Measure the resistance according to the value(s) in the table below.

        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.

    3. Check the commutator for a short circuit.
      GTY459725Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Segment
      *b Starter Armature Core
      1. Measure the resistance according to the value(s) in the table below.

        Standard Resistance

        Tester Connection Condition Specified Condition
        Segment - Starter armature core Always 10 kΩ or higher

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

    4. Using a vernier caliper, measure the commutator length.
      GTY469181Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 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.

  3. INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY 
    1. Check the brush length.
      1. Using a vernier caliper, measure the brush 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.

        GTY503729Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Length
    2. Check the brush insulation.
      GTY464954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Positive (+) Brush
      *b Negative (-) Brush
      1. Measure the resistance according to the value(s) in the table below.

        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.

  4. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY 
    1. Check the gear teeth on the planetary gear, internal gear and starter clutch for wear or damage.

      If worn or damaged, replace the gear or clutch assembly. Also check the drive plate ring gear for wear or damage.

    2. 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.
      GTY464826Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Free
      *b Lock

      If the clutch pinion gear does not operate as specified, replace the starter center bearing clutch sub-assembly.

  5. INSPECT REPAIR SERVICE STARTER KIT 
    1. Check the plunger.
      GTY363679Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Push in the plunger and check that it returns quickly to its original position.

        If the plunger does not operate as specified, replace the repair service starter kit.

    2. Check the pull-in coil for an open circuit.
      GTY514268Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Terminal 50
      *b Terminal C
      1. Measure the resistance according to the value(s) in the table below.

        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.

    3. Check the holding coil for an open circuit.
      GTY510180Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Terminal 50
      *b Magnet Switch Body
      1. Measure the resistance according to the value(s) in the table below.

        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.

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