Starter (for Standard)

1GR-FE STARTING: STARTER (for Standard): INSPECTION

INSPECTION

1. INSPECT STARTER ASSEMBLY

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





(a) Do pull-in test (Condition A).
(1) Disconnect the field coil lead wire from terminal C.
(2) Connect the battery to the magnetic switch as shown. Check that the clutch pinion gear protrudes.





(b) Do holding test.
(1) Disconnect the negative (-) lead from the terminal C with the above condition A is being sustained.
Check that the pinion gear remains protruded.





(c) Inspect clutch pinion gear return.
(1) Disconnect the negative (-) lead from the switch body. Check that the clutch pinion gear returns inward.





(d) Perform the operation test without load.
(1) Connect the field coil lead wire to terminal C.
Torque: 10 Nm (102 kgf-cm, 89 in-lbf)
(2) Hold the starter with a vise.
(3) Connect the battery and ammeter to the starter as shown.
(4) Check that the ammeter indicates the specified current.
Specified current:
90 A or less at 11.5V
2. INSPECT STARTER ARMATURE ASSEMBLY





(a) Check the commutator for open circuit.
(1) Using an ohmmeter, check that there is continuity between the segments of the commutator.
If there is no continuity between any segments, replace the armature.





(b) Check the commutator for ground.
(1) Using an ohmmeter, check that there is no continuity between the commutator and armature coil core.
If there is continuity, replace the armature.
(c) Check the commutator for dirty and burn on surface.
If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe.





(d) Using vernier calipers, measure the commutator length.
Standard length:
3.1 mm (0.122 in.)
Maximum length
3.8 mm (0.150 in.)
If the length is greater than maximum, replace the armature.
3. INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY





(a) Using vernier calipers, measure the brash holder length.
Standard length:
9.0 mm (0.354 in.)
Minimum length
4.0 mm (0.158 in.)
If the length is less than minimum, replace the starter commutator end frame assembly.





(b) Check the brush holder.
(1) Using an ohmmeter, check that there is no continuity between the positive (+) and negative (-) brush holders.
If there is continuity, repair or replace the starter commutator end frame assembly.
4. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY
(a) Inspect the gear teeth of the planetary gear, and the starter center bearing clutch for wear or damage.
If any one of the planetary gear is damaged, replace the planetary gear assembly.
If any one of the gears of the starter center bearing clutch is damaged, replace the clutch.





(b) Check the clutch pinion gear.
(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 necessary, replace the center bearing clutch sub-assembly.
5. INSPECT REPAIR SERVICE STARTER KIT





(a) Check the plunger.
(1) Plush in the plunger and check that it returns quickly to its original position.
If necessary, replace the repair service starter kit.





(b) Check the pull-in coil for open circuit.
(1) Using an ohmmeter, check that there is continuity between terminals 50 and C.
If there is no continuity, replace the repair service starter kit.





(c) Check whether or not the hold-in coil has an open circuit.
(1) Using an ohmmeter, check that there is continuity between terminal 50 and the switch body.
If there is no continuity, replace the repair service starter kit.