Starter Motor: Testing and Inspection

2AZ-FE STARTING: STARTER: INSPECTION

2AZ-FE STARTING: STARTER: INSPECTION

1. INSPECT STARTER ASSEMBLY




NOTICE: These tests must be performed within 3 to 5 seconds to prevent burnout of the coil.

(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 is extended.
If the clutch pinion gear does not move, replace the starter assembly.





(b) Perform the hold-in test.
(1) Disconnect the negative (-) lead from terminal C. Check that the clutch pinion gear remains extended.
If the clutch pinion gear returns inward, replace the starter assembly.





(c) Check the operation.
(1) Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear returns.
If the clutch pinion gear does not return inward, replace the starter assembly.





(d) Perform the no-load performance test.
(1) Connect the lead wire to terminal C. Make sure that the lead is not grounded.
Torque: 10 Nm (100 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 with the clutch pinion gear extended. Check that the ammeter reads the specified current.
Standard current:
90 A or less at 11.5 V
If the result is not as specified, replace the starter.
2. INSPECT STARTER MAGNETIC SWITCH ASSEMBLY





(a) Check the plunger.
(1) Push in the plunger, and then check that it returns quickly to its original position.
OK:
The plunger moves smoothly.
If the result is not as specified, replace the starter assembly.





(b) Check the resistance.
(1) Measure the resistance between terminals 50 and C.
Standard resistance:
Below 1 Ohms
If the result is not as specified, replace the starter assembly.




(2) Measure the resistance between terminals 50 and the body.
Standard resistance:
Below 2 Ohms
If the result is not as specified, replace the starter assembly.
3. INSPECT STARTER ARMATURE ASSEMBLY





(a) Check the resistance.
(1) Measure the resistance between the segments.
Standard resistance:
Below 1 Ohms
If the results is not as specified, replace the starter armature.




(2) Measure the resistance between the segments and coil core.
Standard resistance:
10 kOhms or higher
If the result is not as specified, replace the starter armature.





(b) Check the commutator.
(1) Using a vernier caliper, measure the depth indicated in the illustration.
Standard depth:
3.1 mm (0.122 in.)
Maximum depth:
3.8 mm (0.150 in.)
If the depth is greater than the maximum, replace the starter armature.
4. INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY





(a) Check the brush length.
(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 the minimum, replace the starter assembly.





(b) Check the resistance.
(1) Measure the resistance between resistance the positive (+) and negative (-).
Standard resistance:
10 kOhms or higher
If the results is not as specified, replace the starter assembly.





5. INSPECT STARTER DRIVE HOUSING ASSEMBLY
(a) Check the starter clutch.
(1) Rotate the clutch pinion gear counterclockwise, and then check that it turns freely. Try to rotate the clutch pinion gear clockwise, and then check that it locks.
If necessary, replace the starter assembly.