Starting System (2ZR-FE) (Service Information): Starter: Inspection: Inspection

INSPECT STARTER ASSEMBLY

NOTE:

Perform each of the following tests within 3 to 5 seconds.

Perform a pull-in test.
1. Disconnect the field coil lead wire from terminal C.
2. Connect the battery to the magnet starter switch as shown in the illustration and check that the pinion gear moves outward.
  
  Fig 1: Checking Starter Assembly - Pull In Test
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If the clutch pinion gear does not move, replace the magnet switch assembly.
Perform a hold-in test.
1. Check that the pinion gear does not return inward after the cable is disconnected from terminal C.
  
  Fig 2: Checking Starter Assembly - Hold-In Test
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If the clutch pinion gear returns inward, replace the magnet starter switch assembly.
Inspect the clutch pinion gear return.

Fig 3: Checking Clutch Pinion Gear Movement
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Disconnect the negative (-) lead from the switch body.
  Check that the pinion gear moves inward.
  
  If the clutch pinion gear does not return inward, replace the magnet starter switch assembly.

Perform an operation test without load.

Connect the lead wire to terminal C.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
Clamp the starter in a vise.
Connect the battery and ammeter to the starter as shown in the illustration.

Fig 4: Checking Starter Assembly - With Out Load
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check that the starter rotates smoothly and steadily with the clutch pinion gear extended.

Check that the ammeter indicates the specified current.

Standard Current

Tester Connection	Condition	Specified Condition
Battery positive terminal - Terminal 30 - Terminal 50	11.5 V	Below 90 A

INSPECT MAGNET STARTER SWITCH ASSEMBLY

Check the plunger.

Fig 5: Inspecting Magnet Starter Switch Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Push in the plunger, then check that it returns quickly to its original position.
  If necessary, replace the magnet starter switch assembly.

Inspect the resistance of the pull-in coil.

Fig 6: Measuring Resistance Between Magnet Starter Switch Terminals 50 And C

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using an ohmmeter, measure the resistance between terminals 50 and C.

Standard Resistance

Tester Connection	Condition	Specified Condition
Terminal 50 - Terminal C	-	Below 1 Ω

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

Inspect the resistance of the hold-in coil.

Fig 7: Measuring Resistance Between Magnet Starter Switch Terminals 50 And Switch Body

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using an ohmmeter, measure the resistance between terminal 50 and switch body.

Standard Resistance

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

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

INSPECT STARTER ARMATURE ASSEMBLY

Inspect the resistance of the commutator.

Fig 8: Measuring Resistance Between Segments Of Commutator

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using an ohmmeter, measure the resistance between any 2 segments of the commutator.

Standard Resistance

Tester Connection	Condition	Specified Condition
Segment - Segment	-	Below 1 Ω

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

Check the commutator for a short to ground.

Fig 9: Measuring Resistance Between Commutator And Armature Coil Core

Using an ohmmeter, measure the resistance between the commutator and the armature coil core.

Standard Resistance

Tester Connection	Condition	Specified Condition
Commutator - Armature	-	10 kΩ or higher

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

Check the appearance.
1. If the surface is dirty or burnt, restore the surface with sandpaper (No. 400) or on a lathe.
Check the commutator circuit for runout.

Fig 10: Measuring Circle Runout Using Dial Indicator
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Place the commutator on V-blocks.
2. Using a dial indicator, measure the circle runout.
  Standard runout
  
  0.02 mm (0.000787 in.)
  
  Maximum runout
  
  0.05 mm (0.00197 in.)
  
  If the runout is greater than the maximum, replace the armature assembly.
Using a vernier caliper, measure the commutator diameter.

Fig 11: Measuring Commutator Diameter Using Vernier Calipers
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard diameter

29 mm (1.14 in.)

Minimum diameter

28 mm (1.10 in.)

If the diameter is less than the minimum, replace the armature.
Check that the undercut portion is clean and free of foreign matter. Smooth out the edge.

Fig 12: Measuring Commutator Undercut Depth
Courtesy 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.

INSPECT STARTER BRUSH HOLDER ASSEMBLY

Release the claws of the springs, then remove the 4 brushes.
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 length is less than the minimum, replace the starter brush holder assembly.

Fig 13: Inspecting Starter Brush Holder Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check the brush holder.

Fig 14: Identifying Brushes

Using an ohmmeter, measure the resistance between the brushes.

Standard Resistance

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

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

INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY
1. Inspect the gear teeth on the planetary gear, internal gear and starter clutch for wear or damage.
  If damaged, replace the gear or clutch assembly. Also check the planetary gears for wear or damage.
2. Inspect the starter clutch.
  
  Fig 15: Checking Clutch Pinion Gear Rotation
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 necessary, replace the starter center bearing clutch sub-assembly.