Starting System: Inspection

INSPECT STARTER ASSEMBLY
NOTE: These tests must be performed within 3 to 5 seconds to prevent burnout of the coil.
1. Perform the pull-in test.
  1. Remove the nut, then disconnect the lead wire from terminal C.
    
    Fig 1: Disconnecting Lead Wire From Terminal C
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Connect the battery to the starter repair service kit as shown in the illustration. Check that the clutch pinion gear is extended.
    If the clutch pinion gear is not extended, replace the magnet switch.
    
    Fig 2: Connecting Battery To Starter Repair Service Kit
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. 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, replace the magnet switch.
    
    Fig 3: Disconnecting Negative (-) Lead From Terminal C
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. 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, replace the magnet switch.
    
    Fig 4: Disconnecting Negative (-) Lead From Starter Body
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. 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 N*m (102 kgf*cm, 7 ft.*lbf)
    
    Fig 5: Connecting Lead Wire To Terminal C With Nut
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Clamp the starter in a vise.
  3. Connect the battery and an ammeter to the starter as shown in the illustration.
    
    Fig 6: Connecting Battery And Ammeter To Starter
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 11.5 V
    
    If the current is not as specified, replace the magnet switch.