Starting System (1ZZ-FE): Starter: Inspection

INSPECT STARTER ASSEMBLY
NOTE:
These tests must be performed within 3 to 5 seconds to prevent burnout of the coil.
1. Perform the pull-in test.
  1. Remove the nut, then disconnect the lead wire from terminal C.
  2. Connect the battery to the starter repair service kit as shown in the illustration. Check that the clutch pinion gear is extended.
    If the clutch pinion gear is not extended, replace the magnet switch.
2. Perform the hold-in test.
  1. Disconnect the negative (-) lead from terminal C. Check that the clutch pinion gear remains extended.
    If the clutch pinion gear returns, replace the magnet switch.
3. Check the operation.
  1. Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear returns.
    If the clutch pinion gear does not return, replace the magnet switch.
4. Perform the no-load performance test.
  1. 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)
  2. Clamp the starter in a vise.
  3. Connect the battery and an ammeter to the starter as shown in the illustration.
  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
    
    If the current is not as specified, replace the magnet switch.
INSPECT MAGNET SWITCH BODY
1. Check the operation.
  1. Push in the plunger, then check that it returns quickly to its original position.
    If necessary, replace the magnet switch.
2. Check the resistance.
  1. Using an ohmmeter, check that there is resistance between terminals 50 and C.
    Standard resistance: 1 Ω or lower
    
    If the result is not met, replace the magnet switch.
  2. Using an ohmmeter, check that there is resistance between terminal 50 and the switch body.
    Standard resistance: 2.0 Ω or lower
    
    If the result is not met, replace the magnet switch.
INSPECT STARTER ARMATURE ASSEMBLY
1. Check the resistance.
  1. Using an ohmmeter, check that there is resistance between the segments of the commutator.
    Standard resistance: 1 Ω or lower
    
    If the result is not met, replace the starter armature.
  2. Using an ohmmeter, check that there is no resistance between the commutator and armature coil core.
    Standard resistance: 10 kΩ or higher
    
    If the resistance is not as specified, replace the starter armature.
2. Check the commutator surface for dirt and burn. If the surface is dirty or burnt, smooth the surface with 400-grit sandpaper or lather.
3. Check the commutator depth.
  1. Using vernier calipers, measure the commutator depth.
    Standard depth: 3.1 mm (0.122 in.)
    
    Maximum depth: 3.8 mm (0.150 in.)
    
    If the depth is greater than maximum, replace the starter armature.
INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY
1. Check the brush length.
  1. Using vernier calipers, measure the brush length.
    Standard length: 9.0 mm (0.354 in.)
    
    Minimum length: 4.0 mm (0.158 in.)
    
    If the length is less than minimum, replace the starter commutator end frame.
2. Check the resistance.
  1. Using an ohmmeter, measure the resistance between the positive (+) and negative (-) brushes.
    Standard resistance: 10 kΩ or higher
    
    If the resistance is not as specified, repair or replace the brush holder.
INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY
1. Check the operation.
  1. Turn the clutch pinion gear clockwise, then check that it turns freely. Try to turn the clutch pinion gear counterclockwise, then check that it locks.
    If necessary, replace the starter center bearing clutch.
2. Check for wear and damage.
  1. Check the gear teeth on the planetary gear, internal gear and starter clutch for wear or damage.
    If worn or damaged, replace the starter center bearing clutch.