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Inspection [10/2015 - ]: Procedure

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  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 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.

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

        GTY662411Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Terminal 50
        *b Terminal C
        *c Starter Body
        Moves outward
    2. Perform a hold-in test.
      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.
        GTY672101Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Terminal 50
        *b Terminal C
        *c Starter Body
        Disconnect

        If the clutch pinion gear returns inward, replace the repair service starter kit.

    3. Perform a return test.
      1. Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear returns inward.
        GTY673576Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Terminal 50
        *b Terminal C
        *c Starter Body
        Disconnect
        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 lead wire to terminal C with the nut. Make sure that the 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.
        NOTE:

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

        GTY647481Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Terminal 50
        *b Terminal 30
        *c Starter Body
        Rotates
      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.
      GTY623416Courtesy 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.
      GTY440605Courtesy 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.
      GTY503729Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 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.

    2. Check the brush insulation.
      GTY612458Courtesy 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 
    GTY656170Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Free
    *b Lock
    1. Check the clutch pinion gear.
      1. 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.

        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 return, replace the repair service starter kit.

    2. Check the pull-in coil for an open circuit.
      GTY614250Courtesy 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.
      GTY616140Courtesy 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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