Starter Motor: Testing and Inspection

2AZ-FE STARTING: STARTER: INSPECTION

1. INSPECT STARTER ASSEMBLY

CAUTION:
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 injury.

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

(a) Perform pull-in test:

(1) Disconnect the lead wire from terminal C.





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(2) Connect the battery to the magnetic switch as shown in the illustration. Check that the clutch pinion gear moves outward.





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

(b) Perform holding test:

(1) Disconnect the negative (-) terminal lead from terminal C under the conditions for pull-in test. Check that the pinion gear remains out.





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

(c) Inspect clutch pinion gear return:

(1) Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear moves inward.





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If the clutch pinion gear does not move inward, replace the magnet switch body.

(d) Perform no-load performance test:

(1) Connect the field coil 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 operates.

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(4) Check that the starter rotates smoothly and steadily with the clutch pinion gear extended. Check that the ammeter reads the specified current.

Specified Current:





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

2. INSPECT MAGNET SWITCH BODY

(a) Check the plunger.

(1) Push in the plunger and check that it returns quickly to its original position.





If necessary, replace the magnet switch body.

(b) Inspect the resistance of the pull-in coil.

(1) Measure the resistance according to the value(s) in the table below.





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Standard Resistance:





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

(c) Inspect the resistance of the holding coil.

(1) Measure the resistance according to the value(s) in the table below.





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Standard Resistance:





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

3. INSPECT STARTER ARMATURE ASSEMBLY

HINT
If these in no continuity between any segments, replace the 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.

(b) Check the commutator.

(1) Measure the resistance according to the value(s) in the table below.





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Standard Resistance:





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

(c) Check the commutator.

(1) Measure the resistance according to the value(s) in the table below.





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Standard Resistance:





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

(d) Using a vernier caliper, measure the commutator length.





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Standard length:

3.1 mm (0.122 in.)

Maximum length:

3.8 mm (0.150 in.)

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

4. INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY

(a) Check the brush length.

(1) Using a vernier caliper, measure the brush length.





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Standard length:

9.0 mm (0.354 in.)

Minimum length:

4.0 mm (0.157 in.)

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

(b) Check the resistance.

(1) Measure the resistance according to the value(s) in the table below.





Standard Resistance:





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

5. INSPECT MOTOR TERMINAL STARTER KIT

(a) Check the starter clutch.

(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.





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If necessary, replace the starter drive housing assembly.