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Inspection [10/2022 - ]: 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 lead wire from terminal M.
        GTY1074015Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Once again, install and fasten the removed nut to the terminal M.

        HINT: 

        Make sure the contact area of the terminal M is not floating.

        GTY1180874Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Connect a battery to the repair service starter kit as shown in the illustration. Check that the clutch pinion gear moves outward.

        If the clutch pinion gear does not move outward, replace the repair service starter kit.

        GTY1180947Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Starter Body
        *b Terminal 50
        *c Terminal C
        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.
        GTY1181204Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Starter Body
        *b Terminal 50
        *c Terminal C
        Disconnect

        If the clutch pinion gear returns inward, replace the repair service starter kit.

    3. Perform a return test.
      1. Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear returns inward.
        GTY1180823Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Starter Body
        *b Terminal 50
        Disconnect
        Returns inward

        If the clutch pinion gear does not return inward, replace the repair service starter kit.

    4. Perform a no-load performance test.
      1. Remove the nut from the terminal M.
      2. Connect the lead wire to terminal M with the nut. Make sure that the lead wire is not grounded.

        Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

        GTY1074015Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. 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.

      4. 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.

        GTY1180669Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Starter Body
        *b Terminal 30
        *c Terminal 50
        Rotates
      5. 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 100 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, replace the starter armature assembly.

    2. Check the commutator for an open circuit.
      GTY1020665Courtesy 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.
      GTY1020689Courtesy 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.
      GTY1020667Courtesy 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 (convex part)

        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 CENTER BEARING CLUTCH SUB-ASSEMBLY 
    1. Check the clutch pinion gear.
      GTY845476Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Free
      *b Lock
      1. Rotate the clutch pinion gear clockwise and check that it turns freely. Try to rotate the clutch pinion gear counterclockwise and check that it locks.

        If the clutch pinion gear does not operate as specified, replace the starter center bearing clutch sub-assembly.

  5. INSPECT REPAIR SERVICE STARTER KIT 
    1. Check the plunger.
      GTY181989Courtesy 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 repair service starter kit.

    2. Check the pull-in coil for an open circuit.
      GTY1066266Courtesy 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 repair service starter kit.

    3. Check the holding coil for an open circuit.
      GTY1066030Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Terminal 50
      *b Repair Service Starter Kit Body
      1. Measure the resistance according to the value(s) in the table below.

        Standard Resistance

        Tester Connection Condition Specified Condition
        Terminal 50 - Repair service starter kit body Always Below 2 Ω

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

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