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Inspection [12/2015 - 08/2016]: Procedure

WARNING: This page is about a different car, the 2016 Toyota Sienna. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSPECT STARTER ASSEMBLY 
    NOTE:

    These tests must be performed within 3 to 5 seconds to avoid burning out the coil.

    1. Perform a pull-in test.
      GTY264745Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Remove the nut and disconnect the lead wire from terminal C.
      2. Connect the battery to the magnetic switch as shown in the illustration. Check that the clutch pinion gear is extended.
        GTY431686Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Terminal 50
        *2 Terminal C
        *3 Body

        If the clutch pinion gear does not move, replace the magnetic switch assembly.

    2. Perform a holding test.
      GTY452847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Disconnect the negative (-) lead from terminal C. Check that the clutch pinion gear remains extended.
        TEXT IN ILLUSTRATION

        *1 Terminal 50
        *2 Terminal C
        *3 Body

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

    3. Inspect the clutch pinion gear return.
      GTY424229Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear returns.
        TEXT IN ILLUSTRATION

        *1 Terminal 50
        *2 Terminal C
        *3 Body

        If the clutch pinion gear does not return inward, replace the magnetic switch assembly.

    4. Perform a no-load performance test.
      GTY264745Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
        NOTE:

        Do not clamp the vise too tightly.

      3. Connect the battery and an ammeter to the starter as shown in the illustration.
        GTY706602Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:

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

        TEXT IN ILLUSTRATION

        *1 Terminal 50
        *2 Terminal 30
        *3 Body
      4. Check that the starter rotates smoothly and steadily with the pinion gear extended.
      5. Measure the current according to the value(s) in the table below.

        Standard Current

        Tester Connection Condition Specified Condition
        Battery positive terminal - Terminal 30 11.5 V 90 A or less

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

  2. INSPECT MAGNETIC SWITCH ASSEMBLY 
    1. Check the plunger.
      GTY431042Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Push in the plunger and check that it returns quickly to its original position.
        TEXT IN ILLUSTRATION

        *1 Plunger

        If necessary, replace the magnetic switch assembly.

    2. Check if the pull-in coil for an open circuit.
      GTY310590Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Measure the resistance according to the value(s) in the table below.
        TEXT IN ILLUSTRATION

        *1 Terminal 50
        *2 Terminal C

        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.

    3. Check the holding coil for an open circuit.
      GTY423820Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Measure the resistance according to the value(s) in the table below.
        TEXT IN ILLUSTRATION

        *1 Terminal 50
        *2 Body

        Standard Resistance

        Tester Connection Condition Specified Condition
        Terminal 50 - Body Always Below 2 Ω

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

  3. INSPECT STARTER ARMATURE ASSEMBLY 
    1. Check the commutator for contamination and burns on its surface.

      If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe.

    2. Check the commutator.
      GTY469911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Measure the resistance according to the value(s) in the table below.
        TEXT IN ILLUSTRATION

        *1 Commutator

        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.
      GTY469259Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Measure the resistance according to the value(s) in the table below.
        TEXT IN ILLUSTRATION

        *1 Commutator
        *2 Armature Coil Core

        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.

    4. Using a vernier caliper, measure the commutator length.
      GTY310185Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Length

      Standard length

      3.1 to 3.8 mm (0.122 to 0.149 in.)

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

  4. INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY 
    1. Using a vernier caliper, measure the brush length.
      GTY450592Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Length

      Standard length

      4.0 to 9.0 mm (0.158 to 0.354 in.)

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

    2. Check the brush insulation.
      GTY270945Courtesy 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
        Positive brush holder - Negative brush holder Always 10 kΩ or higher

        If the result is not as specified, replace the starter commutator end frame assembly.

  5. INSPECT STARTER CLUTCH SUB-ASSEMBLY 
    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.
      GTY724570Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Lock
      *b Free

      If necessary, replace the repair service starter kit.

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