Starter Motor: Testing and Inspection

2ZR-FE STARTING: STARTER: INSPECTION

INSPECTION

1. INSPECT STARTER ASSEMBLY
NOTE: The following tests must be performed for no longer then 5 seconds to prevent the coil from burning out.

(a) Perform the pull-in test.
(1) Remove the nut and disconnect the lead wire from terminal C.





(2) Connect the battery to the starter magnetic switch as shown in the illustration. Check that the clutch pinion gear moves outward.
If the result is not as specified, replace the magnet starter switch assembly.






(b) Perform the holding test.
(1) Disconnect the negative (-) lead from terminal C. Check that the pinion gear remains out.
If the result is not as specified, replace the magnet starter switch assembly.






(c) Check the operation.
(1) Disconnect the negative (-) lead from the switch body. Check that the clutch pinion gear returns in ward.
If the result is not as specified, replace the magnet starter switch assembly.
(d) Perform the 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.





(3) Connect the battery and an ammeter to the starter as shown in the illustration.
(4) Check that the starter rotates smoothly and steadily while the pinion gear is moving out.
Check that the ammeter reads the specified current.
Standard current:






If the result is not as specified, replace the starter assembly.
2. INSPECT STARTER ARMATURE ASSEMBLY






(a) Inspect the commutator for open circuits.
(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 armature assembly.






(b) Inspect the commutator for ground.
(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 armature assembly.
(c) Inspect the commutator surface for dirt and burns.
If the surface is dirty or burnt, restore 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 the maximum, replace the armature assembly.
3. INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY





(a) 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 the minimum, replace the starter commutator end frame assembly.






(b) Inspect the brush holder.
(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.
4. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY
(a) Inspect the gear teeth on the planetary gear, internal gear and starter clutch for wear and damage.
If damaged, replace the starter planetary gear or starter center bearing clutch sub-assembly. Also check the starter planetary gear for wear or damage.






(b) Inspect the starter clutch.
(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.
5. INSPECT MAGNET SWITCH BODY





(a) Inspect 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 pull-in coil for open circuits.
(1) Measure the resistance according to the value (s) in the table below.
Standard resistance:






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






(c) Check whether the holding coil has an open circuit.
(1) Measure the resistance according to the value (s) in the table below.
Standard resistance:






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