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Inspection [06/2017 - ]: 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 field coil lead wire from terminal C.
      2. Connect a battery to the magnet starter switch assembly as shown in the illustration. Check that the clutch pinion gear moves outward.

        If the clutch pinion gear does not move outward, replace the magnet starter switch assembly.

        GTY761624Courtesy 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.
        GTY762324Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Terminal 50
        *b Terminal C
        *c Starter Body
        Disconnect

        If the clutch pinion gear returns inward, replace the magnet starter switch assembly.

    3. Perform a return test.
      1. Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear returns inward.
        GTY764214Courtesy 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 magnet starter switch assembly.

    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. GTY766341Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Terminal 50
        *b Terminal 30
        *c Starter Body
        Rotates

        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.

      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.
      GTY764413Courtesy 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.
      GTY765706Courtesy 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.
      GTY755320Courtesy 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.

      Standard Diameter

      29 mm (1.14 in.)

      Minimum Diameter

      28 mm (1.10 in.)

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

      GTY503849Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Check that the undercut portion between the segments is free of foreign matter and measure its depth.

      Standard Undercut Depth

      0.7 mm (0.0276 in.)

      Minimum Undercut Depth

      0.2 mm (0.00787 in.)

      If the undercut depth is less than the minimum, adjust it with a hacksaw blade.

      GTY511994Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSPECT STARTER BRUSH HOLDER ASSEMBLY 
    1. Check the brush length.
      1. Using a vernier caliper, measure the brush length.

        Standard Length

        14.4 mm (0.567 in.)

        Minimum Length

        9.0 mm (0.354 in.)

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

        GTY496625Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Brush Length
    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.

  4. INSPECT STARTER CLUTCH 
    GTY768595Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Lock
    Free
    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 repair service starter kit.

  5. INSPECT MAGNET STARTER SWITCH ASSEMBLY 
    1. Check the plunger.
      GTY188770Courtesy 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 magnet starter switch assembly.

    2. Check the pull-in coil for an open circuit.
      GTY764048Courtesy 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 magnet starter switch assembly.

    3. Check the holding coil for an open circuit.
      GTY761644Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Terminal 50
      *b Magnet Starter Switch Assembly Body
      1. Measure the resistance according to the value(s) in the table below.

        Standard Resistance

        Tester Connection Condition Specified Condition
        Terminal 50 -Magnet starter switch assembly body Always Below 2 Ω

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

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