Section 27 (Starting System (Service Information)): Starter: Inspection: Inspection

WARNING: This page is about a different car, the 2011 Toyota Avalon. However, it is still accessible from the selected car via links, so may be relevant.

INSPECT STARTER ASSEMBLY
NOTE:
These tests must be performed within 3 to 5 seconds to avoid burning out the coil.
1. Perform the pull-in test.
  
  Fig 1: Checking Perform Pull-In Test
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Disconnect the lead wire from terminal C.
  2. Connect the battery to the magnetic switch as shown in the illustration above. Check that the clutch pinion gear extends.
    If the clutch pinion gear does not move, replace the magnetic switch.
2. Perform the hold-in test.
  
  Fig 2: Checking Perform Hold-In Test
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Maintain the battery connections in step (a), but 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.
3. Check the clutch pinion gear return.
  
  Fig 3: Checking Clutch Pinion Gear Return
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
4. Perform the no-load performance test.
  
  Fig 4: Inspecting Starter Assembly (No-Load Performance Test)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Connect the lead wire to terminal C. Make sure that the lead is not grounded.
  2. Clamp the starter in a vise.
  3. Connect the battery and an ammeter to the starter as shown in the illustration.
  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
    
    90 A or less at 11.5V
    
    If the result is not as specified, replace the starter assembly.
INSPECT REPAIR SERVICE STARTER KIT
1. Check the plunger.
  
  Fig 5: Checking Plunger
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Push in the plunger and check that it returns quickly to its original position.
    If necessary, replace the repair service starter kit.
2. Check the resistance.
  
  Fig 6: Measuring Resistance Between Terminals 50 And C
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Using an ohmmeter, measure the resistance between terminals 50 and C.
    Resistance
    
    below 1 Ω
    
    If the result is not as specified, replace the repair service starter kit.
3. Using an ohmmeter, measure the resistance between terminal 50 and the starter kit body.
  
  Fig 7: Measuring Resistance Between Terminal 50 And Starter Kit Body
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Resistance
  
  below 2 Ω
  
  If the result is not as specified, replace the repair service starter kit.
INSPECT STARTER ARMATURE ASSEMBLY
1. Check the resistance.
  
  Fig 8: Measuring Resistance Between Segments Of Commutator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Using an ohmmeter, measure the resistance between the segments of the commutator.
    Resistance
    
    below 1 Ω
    
    If the result is not as specified, replace the starter armature.
2. Using an ohmmeter, measure the resistance between the segment of the commutator and armature coil core.
  
  Fig 9: Measuring Resistance Between Segment Of Commutator And Armature Coil Core
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Resistance
  
  10 kΩ or higher
  
  If the result is not as specified, replace the starter armature.
3. Check the commutator surface for dirt or burning.
  If the surface is dirty or burnt, smooth the surface with 400-grit sandpaper or leather.
4. Check the commutator depth.
  
  Fig 10: Identifying Commutator Depth
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Using vernier calipers, measure the commutator depth.
    Standard depth
    
    3.1 mm (0.122 in.)
    
    Maximum depth
    
    3.8 mm (0.150 in.)
    
    If the length is greater than the maximum, replace the starter armature assembly.
INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY
1. Check the brush length.
  
  Fig 11: Identifying Brush Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Using vernier calipers, measure the brush 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.
2. Check the resistance.
  
  Fig 12: Measuring Resistance Between Positive (+) And Negative (-) Brushes
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Using an ohmmeter, measure the resistance between the positive (+) and negative (-) brushes.
    Resistance
    
    10 KΩ or higher
    
    If the resistance is not as specified, repair or replace the starter commutator end frame.
INSPECT MOTOR TERMINAL STARTER KIT
1. Check the starter clutch.
  
  Fig 13: Checking Clutch Pinion Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Rotate the clutch pinion gear counterclockwise and check that it turns freely. Try to rotate the clutch pinion gear clockwise. Check that it locks.
    If necessary, replace the motor terminal starter kit.