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Inspection [09/2015 - ]: Procedure

  1. INSPECT STARTER ASSEMBLY 
    WARNING:

    As a large electric current passes through the cable during this inspection, a thick cable must be used. Otherwise, the cable may become hot and cause injury.

    NOTE:

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

    1. Perform a pull-in test.
      1. Disconnect the field coil wire from terminal C.
      2. Connect the battery to the magnetic switch as shown in the illustration. Check that the clutch pinion gear moves outward.
        GTY630075Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Terminal 50
        *b Terminal C

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

    2. Perform a holding test.
      1. Disconnect the negative (-) terminal lead from terminal C while maintaining the condition specified for the pull-in test above. Check that the pinion gear remains out.
        GTY653496Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Terminal C
        Disconnect

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

    3. Inspect the clutch pinion gear return.
      1. Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear returns inward.
        GTY644574Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Disconnect

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

    4. Perform an operation test without load.
      1. Connect the field coil wire to terminal C with the nut. Make sure that the lead is not grounded.
        GTY666588Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Terminal 50
        *b Terminal 30

        Torque: 6.5 N*m (66 kgf*cm, 58 in.*lbf) 

      2. Mount the starter in a vise between aluminum plates.
      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 outward. Then measure the current.

        Standard current

        190 A or less at 11.5 V

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

  2. INSPECT STARTER ARMATURE ASSEMBLY 
    1. 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. If necessary, replace the starter armature assembly.

    2. Inspect the resistance of the commutator.
      1. Measure the resistance according to the value(s) in the table below.
        GTY105154Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        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.

      2. Measure the resistance according to the value(s) in the table below.
        GTY104224Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Standard Resistance

        Tester Connection Condition Specified Condition
        Segment - Coil core Always 10 kΩ or higher

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

    3. Check the commutator circle runout.
      1. Place the armature shaft on V-blocks.
        GTY102917Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Using a dial indicator, measure the circle runout.

        Maximum runout

        0.05 mm (0.00197 in.)

        If the commutator runout is greater than the maximum, correct it using a lathe.

    4. Using a vernier caliper, measure the commutator diameter.
      GTY102581Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard diameter

      35.0 mm (1.38 in.)

      Minimum diameter

      34.0 mm (1.34 in.)

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

    5. Check that the undercut portion is clean and free of foreign matter. Smooth out the edge.
      GTY175866Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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, increase the depth using a hacksaw blade.

  3. INSPECT STARTER YOKE ASSEMBLY 
    1. Inspect the resistance of the field coil.
      1. Measure the resistance between the lead wire and field coil brush lead.
        GTY673870Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Standard Resistance

        Tester Connection Condition Specified Condition
        Brush - Lead wire Always Below 1 Ω

        If the resistance is not as specified, repair or replace the starter yoke assembly.

      2. Measure the resistance between the field coil brush lead and field frame.
        GTY618784Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Standard Resistance

        Tester Connection Condition Specified Condition
        Brush - Field frame Always 10 kΩ or higher

        If the resistance is not as specified, repair or replace the starter yoke assembly.

  4. INSPECT BRUSH 
    1. Using a vernier caliper, measure the brush length.
      GTY650821Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a for Brush Holder Side
      *b for Yoke Side
      *c Length

      Standard length

      15.0 mm (0.591 in.)

      Minimum length

      10.0 mm (0.394 in.)

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

  5. INSPECT STARTER BRUSH HOLDER ASSEMBLY 
    1. Inspect the insulation.
      GTY625367Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Measure the resistance between the positive (+) and negative (-) brush holders.

        Standard Resistance

        Tester Connection Condition Specified Condition
        Positive (+) brush holder - Negative (-) brush holder Always 10 kΩ or higher

        If the resistance is not as specified, replace thestarter brush holder assembly.

    2. Inspect the load of the brush spring.
      1. Take a pull scale reading immediately after the brush spring separates from the brush.
        GTY629870Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Brush
        *b Brush Spring

        Standard spring load

        21.5 to 27.5 N (2.2 to 2.8 kgf, 4.8 to 6.2 lbf)

        Minimum spring load

        12.7 N (1.3 kgf, 2.9 lbf)

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

  6. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY 
    1. Check the gear teeth on the planetary gears, and the internal gear and pinion gear of the starter center bearing clutch for wear or damage.

      If any of the gears is damaged, replace the gear or starter center bearing clutch sub-assembly.

    2. Check the movement of the clutch pinion gear.
      GTY656827Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Free
      Lock
      1. Rotate the clutch pinion gear clockwise, and check that it turns freely.
      2. Try to rotate the clutch pinion gear counterclockwise, and check that it locks.

        If the clutch pinion gear cannot be turned clockwise smoothly, or does not lock in the counterclockwise direction, replace the starter center bearing clutch sub-assembly.

  7. INSPECT MAGNET STARTER SWITCH ASSEMBLY 
    1. Check the operation.
      1. Push in the plunger, and then check that it returns quickly to its original position.
        GTY520687Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        If necessary, replace the magnet starter switch assembly.

    2. Check if the pull-in coil has an open circuit.
      1. Measure the resistance according to the value(s) in the table below.
        GTY612568Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Terminal 50
        *b 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 magnet starter switch assembly.

    3. Check if the holding coil has an open circuit.
      1. Measure the resistance according to the value(s) in the table below.
        GTY618936Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Terminal 50
        *b Switch Body

        Standard Resistance

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

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

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