LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2014 >> Highlander XLE, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 9 (Starting System [2GR-FKS] (W/ Stop And Start) - Service Information - (Except Hybrid)) >> STARTER (w/ Stop And Start System) >> Inspection [11/2016 - ] >> Procedure

Inspection [11/2016 - ]: Procedure

WARNING: This page is about a different car, the 2019 Toyota Highlander, 2018 Toyota Highlander, and 2017 Toyota Highlander. 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 no-load performance test.
      1. Connect the positive (+) lead to terminal SL1.
        GTY721279Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Starter Body
        Moves outward
      2. Connect the negative (-) lead to the starter body and check that the clutch pinion gear moves outward.
        NOTE:

        If the positive (+) and negative (-) leads are connected incorrectly, the IC inside the starter inrush current reduction relay will be damaged. Be sure to connect them correctly.

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

      3. With the clutch pinion gear in the outward position, disconnect the negative (-) lead and check that the clutch pinion gear returns inward.
        GTY725494Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Starter Body
        Disconnect
        Returns inward

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

      4. Connect the positive (+) lead to terminal SL2 of the connector and the negative (-) lead to the starter body. Check that a clicking sound is heard from the starter motor.
        GTY687025Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Starter Body

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

      5. 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.

      6. Connect the battery and an AC/DC 400A probe to the starter assembly as shown in the illustration.
        GTY694100Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Starter Body *b Terminal 30
        *c AC/DC 400A Probe - -
        Rotates - -
      7. Connect terminal SL2 and measure the current after the AC/DC 400A probe reading has stabilized.

        Standard Current

        Tester Connection Condition Specified Condition
        Battery positive (+) terminal - Terminal 30 - Terminal SL2 11.5 V Below 130 A

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

  2. INSPECT STARTER ARMATURE ASSEMBLY 
    1. Check the commutator appearance.

      If the surface is dirty or burnt, replace the armature assembly.

    2. Check the commutator for an open circuit.
      GTY726386Courtesy 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.
      GTY709465Courtesy 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. Check the commutator for runout.
      GTY724232Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Armature Shaft
      1. Place the armature shaft on V-blocks.
      2. Using a dial indicator, measure the runout.

        Maximum Runout

        0.05 mm (0.00197 in.)

        If the runout is greater than the maximum, replace the starter armature assembly.

    5. Using a vernier caliper, measure the commutator diameter.
      GTY712540Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Diameter (convex part)

      29 mm (1.1417 in.)

      Minimum Diameter (convex part)

      28 mm (1.1024 in.)

      If the diameter is less than the minimum, replace the starter armature assembly.

    6. Check that the undercut portion between the segments is free of foreign matter and measure its depth.
      GTY721155Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Undercut Depth (convex part)

      0.7 mm (0.0276 in.)

      Minimum Undercut Depth (convex part)

      0.4 mm (0.0157 in.)

      If the undercut depth is less than the minimum, replace the starter armature assembly.

  3. INSPECT STARTER BRUSH HOLDER ASSEMBLY 
    1. Check the brush length.
      GTY711441Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Length
      1. Using a vernier caliper, measure the brush length.

        Standard Length (convex part)

        14.4 mm (0.567 in.)

        Minimum Length (convex part)

        9.0 mm (0.354 in.)

        If the length is less than the minimum, replace the starter brush holder assembly.

    2. Check the brush holder resistance.
      GTY506660Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Measure the resistance according to the value(s) in the table below.

        Standard Resistance

        Tester Connection Condition Specified Condition
        A - B
        A - C
        B - D
        C - D        		 Always 10 kΩ or higher
        A - D
        B - C        		 Below 1 Ω

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

    3. Check the brush spring load.
      1. Take a pull scale reading the instant the brush spring separates from the brush.
        GTY500692Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Standard Spring Load

        22.3 to 27.3 N (2.27 to 2.78 kgf, 5.01 to 6.14 lbf)

        Minimum Spring Load

        13.8 N (1.41 kgf, 3.1 lbf)

        If the spring load is less than the minimum, replace the starter brush holder assembly.

  4. INSPECT STARTER CLUTCH 
    GTY687732Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Free
    *b Lock
    1. Check the clutch pinion gear.
      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 the clutch pinion gear does not operate as specified, replace the starter drive housing assembly.

  5. INSPECT REPAIR SERVICE STARTER KIT 
    GTY215680Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Check the plunger.
      1. Push in the plunger and check that it returns quickly to its original position.
        NOTE:

        Do not drop the plunger.

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

    2. Check the repair service starter kit resistance.
      GTY690497Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Magnet Switch Body
      1. Measure the resistance according to the value(s) in the table below.

        Standard Resistance

        Tester Connection Condition Specified Condition
        Terminal SL1 - Magnet switch body Always Below 1 Ω
        Terminal SL2 - Magnet switch body Below 2 Ω

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

scientia non olet · About LEMON Manuals