Section 10 (Starting System (1AR-FE)): Starter: Inspection

WARNING: This page is about a different variant/trim than selected.

INSPECT STARTER ASSEMBLY
NOTE: These tests must be performed within 3 to 5 seconds to avoid burning out the coil.

Fig 1: Locating Planetary Gears In Starter Drive Housing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Perform a pull-in test.
  1. Remove the nut and disconnect the lead wire from terminal C.
  2. Connect the battery to the magnet starter switch assembly as shown in the illustration. Check that the clutch pinion gear extends. If the clutch pinion gear does not move, replace the magnet starter switch assembly.
  Fig 2: Connecting Battery To Magnet Starter Switch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Perform a hold-in test.
  1. While maintaining the battery connections of the pull-in test above, disconnect the negative (-) lead from terminal C. Check that the pinion gear remains extended.
    If the clutch pinion gear returns inward, replace the magnet starter switch assembly.
    
    Fig 3: Identifying Starter - Hold-In Test
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. check the clutch pinion gear return test.
  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 starter switch assembly.
    
    Fig 4: Identifying Starter - Clutch Pinion Gear Return Test
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Perform a 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)
    
    Fig 5: Identifying Starter - No-Load Performance Test
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 while the pinion gear is moving out. Then measure the current.
    Standard current:
    
    90 A or less at 11.5 V
    
    If the result is not as specified, replace the starter assembly.

INSPECT MAGNETIC SWITCH ASSEMBLY

Check the plunger.
1. Push in the plunger and check that it returns quickly to its original position.
  If necessary, replace the magnetic switch assembly.
  
  Fig 6: Checking Plunger
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check if the pull-in coil has an open circuit.

Measure the resistance between terminals 50 and C.
Standard Resistance

STANDARD RESISTANCE

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

If the result is not as specified, replace the magnetic switch assembly.

Fig 7: Checking Pull-In Coil Has An Open Circuit

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check if the hold-in coil has an open circuit.

Measure the resistance between terminal 50 and the switch body.
Standard Resistance

STANDARD RESISTANCE

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

If the result is not as specified, replace the magnetic switch assembly.

Fig 8: Checking Hold-In Coil Has An Open Circuit

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT STARTER ARMATURE ASSEMBLY

HINT:

If there is no commutator between any segment, replace the starter armature assembly.

Check the surface of the commutator for dirt and burns.
If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe.

Inspect the commutator for an open circuit.

Measure the resistance between the segments of the segment.
Standard Resistance

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.

Fig 9: Inspecting Commutator For An Open Circuit

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check if the commutator is grounded.

Measure the resistance between the commutator and armature coil core.
Standard Resistance

STANDARD RESISTANCE

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

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

Fig 10: Checking Commutator Is Grounded

Using a vernier caliper, measure the commutator length.
Standard length:

3.1 to 3.8 mm (0.122 to 0.149 in.)

Maximum length:

3.8 mm (0.149 in.)

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

Fig 11: Identifying Commutator Length
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY

Using a vernier caliper, measure the brush length.
Standard length:

4.0 to 9.0 mm (0.158 to 0.354 in.)

Minimum length:

4.0 mm (0.158 in.)

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

Fig 12: Identifying Brush Length
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Inspect the insulation.

Measure the resistance according to the value(s) in the table below.
Standard Resistance

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.

Fig 13: Inspecting Insulation

INSPECT STARTER CLUTCH
1. Check the starter clutch.
  1. Rotate the clutch pinion gear counterclockwise and check that it turns freely. Try to rotate the clutch pinion gear clockwise and check that it locks.
    If necessary, replace the starter repair the starter drive housing assembly.
    
    Fig 14: Checking Starter Clutch
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002