Starter Motor: Testing and Inspection
2GR-FE STARTING: STARTER: INSPECTION
1. INSPECT STARTER ASSEMBLY
NOTICE:
These tests must be performed within 3 to 5 seconds to avoid burning out the coil.
(a) Perform a pull-in test.
(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 extends.
Text in Illustration
(2) If the clutch pinion gear does not move, replace the magnetic switch assembly.
(b) Perform a hold-in test.
Text in Illustration
(1) While maintaining the battery connections of the pull-in test above, disconnect the negative (-) lead from terminal C. Check that the pinion gear remains extended.
If the clutch pinion gear returns inward, replace the magnetic switch assembly.
(c) Perform a clutch pinion gear return test.
Text in Illustration
(1) Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear returns.
If the clutch pinion gear does not return, replace the magnetic switch assembly.
(d) Perform a no-load performance test.
(1) Connect the lead wire to terminal C with the nut. Make sure that the lead is not grounded.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(2) Clamp the starter in a vise.
NOTICE:
Ensure that the starter is secured firmly in the vise to prevent it from falling out.
(3) Connect the battery and an ammeter to the starter as shown in the illustration.
NOTICE:
Do not allow any lead to get caught as the pinion gear rotates.
Text in Illustration
(4) Check that the starter rotates smoothly and steadily while the pinion gear is moving out. Then measure the current.
Standard current:
90 A or less at 11.5 V
(4) If the result is not as specified, replace the starter assembly.
2. INSPECT MAGNETIC SWITCH ASSEMBLY
(a) Check the plunger.
(1) Push in the plunger and check that it returns quickly to its original position.
If necessary, replace the magnetic switch assembly.
(b) Check if the pull-in coil has an open circuit.
Text in Illustration
(1) Measure the resistance between terminals 50 and C.
Standard Resistance:
Below 1 Ohms
(1) If the result is not as specified, replace the magnetic switch assembly.
(c) Check if the hold-in coil has an open circuit.
Text in Illustration
(1) Measure the resistance between terminal 50 and the switch body.
Standard Resistance:
Below 2 Ohms
(1) If the result is not as specified, replace the magnetic switch assembly.
3. INSPECT STARTER ARMATURE ASSEMBLY
(a) 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.
(c) Check if the commutator has an open circuit.
Text in Illustration
(1) Measure the resistance between the segments of the commutator.
Standard Resistance:
Below 1 Ohms
(1) If the result is not as specified, replace the starter armature assembly.
(d) Check if the commutator is grounded.
Text in Illustration
(1) Measure the resistance between the commutator and armature coil core.
Standard Resistance:
10 kOhms or higher
(1) If the result is not as specified, replace the starter armature assembly.
(e) Using a vernier caliper, measure the commutator length.
Text in Illustration
Standard length:
3.1 to 3.8 mm (0.122 to 0.149 in.)
(f) If the length is greater than the maximum, replace the starter armature assembly.
4. INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY
(a) Using a vernier caliper, measure the brush length.
Text in Illustration
Standard length:
4.0 to 9.0 mm (0.158 to 0.354 in.)
(b) If the length is less than the minimum, replace the starter commutator end frame assembly.
(c) Check the brush insulation.
(1) Measure the resistance between the positive (+) and negative (-) brushes.
Standard Resistance:
10 kOhms or higher
(1) If the result is not as specified, replace the starter commutator end frame assembly.
5. INSPECT STARTER CLUTCH
Text in Illustration
(a) 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 necessary, replace the repair service starter kit.