Starter Motor: Testing and Inspection

2UZ-FE STARTING: STARTER: INSPECTION

INSPECTION

1. INSPECT STARTER ASSEMBLY
NOTE: The following tests must be done within 3 to 5 seconds to prevent the coil from burning out.

(a) Perform pull-in test.





(1) Remove the nut, and then 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 moves outward.
If the clutch pinion gear does not move, replace the magnet starter switch assembly.






(b) Perform holding test.
(1) With the battery connected as above with the clutch pinion gear out, disconnect the negative (-) lead from terminal C. Check that the pinion gear remains out.
If the clutch pinion gear returns inward, replace the magnet starter switch assembly.






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






(d) Perform the operation test without load.
(1) Connect the field coil lead wire to terminal C.
Torque: 5.9 Nm (60 kgf-cm, 52 in-lbf)
(2) Grip the starter in a vise.
(3) Connect the battery and an ammeter to the starter as shown.
(4) Check that the starter rotates smoothly and steadily with the clutch pinion gear extended.
(5) Check that the ammeter reads the specified current.
Standard current:
100 A or less at 11.5 V
If the result is not as specified, replace the starter assembly.
2. INSPECT STARTER ARMATURE ASSEMBLY






(a) Inspect the commutator for 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 armature assembly.






(b) Inspect the commutator for a short 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 armature assembly.
(c) Inspect the commutator circle runout.





(1) Place the commutator on V-blocks.
(2) Using a dial indicator, measure the circle runout.
Maximum circle runout:
0.05 mm (0.00197 in.)
If the runout is greater than the maximum, correct it with sandpaper (#400) or replace the armature assembly.






(d) Using a vernier caliper, measure the commutator diameter.
Standard diameter:
35.0 mm (1.38 in.)
Minimum diameter:
34.0 mm (1.34 in.)
If the diameter is less than the minimum, replace the armature assembly.






(e) Measure the undercut depth of the commutator.
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, correct it with a hacksaw blade.
(f) Inspect the bearing.
(1) Check that the bearing rotates smoothly.
If the result is not as specified, replace the starter armature assembly.
3. INSPECT STARTER YOKE ASSEMBLY






(a) Inspect for 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 starter yoke assembly.






(b) Inspect the shunt coil for 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 starter yoke assembly.
4. INSPECT BRUSH






(a) Using a vernier caliper, measure the brush length.
Standard length:
15.0 mm (0.591 in.)
Minimum length:
9.0 mm (0.354 in.)
If the length is less than the minimum, replace the brush holder and starter yoke assembly.
5. INSPECT STARTER BRUSH HOLDER ASSEMBLY






(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:





If the result is not as specified, replace the brush holder.






(b) Inspect the load of the brush spring.
(1) Take the pull scale reading immediately after the brush spring separates from the brush.
Standard spring installed load:
21.5 to 27.5 N (2.2 to 2.8 kgf, 4.9 to 6.2 lbf)
Minimum spring installed load:
12.7 N (1.3 kgf, 2.9 lbf)
If the spring load is less than the minimum, replace the brush holder.
6. INSPECT STARTER CLUTCH SUB-ASSEMBLY






(a) Check that the starter clutch cannot be rotated counterclockwise, and can be rotated clockwise.
If the starter clutch is not as specified, replace the starter clutch sub-assembly.
(b) Turn the bearing by hand while applying inward force.
If resistance is felt or the bearing sticks, replace the bearing.
7. INSPECT MAGNETIC STARTER SWITCH ASSEMBLY






(a) Inspect the pull-in coil.
(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 starter switch assembly.






(b) Inspect the holding coil.
(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 starter switch assembly.