Starter (for Cold Area)

1NR-FE STARTING: STARTER (for Cold Area): INSPECTION

1. INSPECT STARTER ASSEMBLY

NOTICE:
The following tests must be performed within 5 seconds to prevent the coil from burning out.

(a) Perform a pull-in test.





(1) Remove the nut and disconnect the lead wire from terminal C.

(2) Connect the battery to the magnet starter switch as shown in the illustration. Check that the clutch pinion gear is extended.





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If the clutch pinion gear does not move, replace the magnet starter switch assembly.

(b) Perform a holding test.





(1) Disconnect the negative (-) lead from terminal C. Check that the clutch pinion gear remains extended.

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If the clutch pinion gear returns inward, replace the magnet starter switch assembly.

(c) Inspect the clutch pinion gear return.





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

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If the clutch pinion gear does not return inward, replace the magnet starter switch assembly.

(d) Perform a no-load performance test.





(1) Connect the lead wire to terminal C. 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:
Do not clamp the vise too tightly.

(3) Connect the battery and an ammeter to the starter as shown in the illustration.





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

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

Standard Current:





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

2. INSPECT STARTER ARMATURE ASSEMBLY

(a) 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.

(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 surface for dirt and burns.

If the surface is dirty or burnt, restore it with sandpaper (No. 400) or a lathe.

(d) Check the commutator for circle runout.

(1) Place the commutator on V-blocks.





(2) Using a dial indicator, measure the circle runout.

Maximum runout:

0.05 mm (0.00197 in.)

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

(e) Using a vernier caliper, measure the commutator diameter.





Standard diameter:

29.0 mm (1.14 in.)

Minimum diameter:

28.0 mm (1.10 in.)

If the diameter is less than the minimum, replace the starter armature assembly.

(f) Check that the undercut portion between the segments is free of foreign matter and measure its depth.





Standard undercut depth:

0.7 mm (0.0276 in.)

Minimum undercut depth:

0.2 mm (0.00787 in.)

If the undercut depth is less than the minimum, adjust it with a hacksaw blade.

3. INSPECT STARTER BRUSH HOLDER ASSEMBLY

(a) Remove the claw of the spring, and then remove the 4 brushes.

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





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Standard length:

14.4 mm (0.567 in.)

Minimum length:

9.0 mm (0.354 in.)

If the length is less than the minimum, replace the starter brush holder assembly.

(c) Check 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 brush holder.

4. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY

(a) 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.





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If necessary, replace the starter center bearing clutch sub-assembly.

5. INSPECT MAGNET STARTER SWITCH ASSEMBLY

(a) Check the plunger.

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





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If necessary, replace the magnet starter switch assembly.

(b) Check the pull-in coil for an open circuit.

(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 starter switch assembly.

(c) Check the holding coil for an open circuit.

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





Text in Illustration





Standard Resistance:





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