Starter Motor: Testing and Inspection

2UZ-FE STARTING: STARTER: INSPECTION

INSPECTION

1. INSPECT STARTER ASSEMBLY
NOTE:
These tests must be done within 3 to 5 seconds to avoid burning out the coil.

(a) Do pull-in test.




(1) 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.





(b) Do holding test.
(1) With battery connected as above with the clutch pinion gear out, disconnect the negative (-) lead from terminal C. Check that the pinion gear remains out.





(c) Inspect clutch pinion gear return.
(1) Disconnect the negative (-) lead from the switch body. Check that the clutch pinion gear returns inward.





(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 ammeter to the starter as shown.
(4) Check that the ammeter reads the specified current.
Specified current :
100 A or less at 11.5 V
2. INSPECT STARTER ARMATURE ASSEMBLY
(a) Inspect commutator for dirty and burnt surface.
If the surface of the commutator is dirty or burned, polish the part with sandpaper (No. 400) or replace the armature.





(b) Inspect commutator for open circuit.
(1) Using an ohmmeter, check that there is continuity between the segments of the commutator.
If there is no continuity between any segments, replace the armature.





(c) Inspect commutator for ground.
(1) Using an ohmmeter, check that there is no continuity between the commutator and armature core.
If there is continuity, replace the armature assembly.
(d) Inspect commutator circle runout.




(1) Place the armature on the V-blocks.
(2) Using a dial gauge, measure the circuit runout.
Maximum circle runout:
0.05 mm (0.0020 in.)
If the circle runout is greater than maximum, correct it on a lathe.





(e) Using vernier calipers, measure the commutator diameter.
Standard diameter:
35.0 mm (1.378 in.)
Minimum diameter
34.0 mm (1.339 in.)
If the diameter is less than minimum, replace the armature assembly.





(f) Measure the undercut depth of commutator.
Standard undercut depth:
0.7 mm (0.028 in.)
Minimum undercut depth
0.2 mm (0.008 in.)
If the undercut depth is less than the minimum, correct it with a hacksaw blade.
(g) Inspect the bearings.
(1) Check that the bearing rotates smoothly.
3. INSPECT STARTER YOKE ASSEMBLY





(a) Inspect field coil for open circuit.
(1) Using an ohmmeter, check that there is continuity between the lead wire and field coil brush lead.
If there is no continuity, replace the starter yoke assembly.





(b) Inspect shunt coil for open circuit.
(1) Using an ohmmeter, measure the resistance between shunt coil terminals (A) and (B).
Standard resistance:
1.5 to 1.9 Ohms at 20°C (68°F)
If the resistance is not as specified, replace the starter yoke assembly.
4. INSPECT BRUSH





(a) Using vernier calipers, 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) Using an ohmmeter, check that there is no continuity between the positive and negative brush holders.
If there is continuity, replace the brush holder.





(b) Take the pull scale reading the instant the brush spring separates from the brush.
Standard spring installed load:
21.5 to 27.5 N (2.2 to 2.8 kgf, 4.8 to 6.2 lbf)
Minimum spring installed load
12.7 N (1.3 kgf, 2.9 lbf)
If spring load is less than the minimum, replace the brush springs.
6. INSPECT STARTER CLUTCH SUB-ASSEMBLY





(a) Rotate the pinion gear clockwise, and check that it turns freely. Try to rotate the pinion gear counterclockwise and check that it locks.
If necessary, replace the clutch sub-assembly.
7. INSPECT STARTER MAGNETIC SWITCH ASSEMBLY





(a) Check the pull-in coil continuity.
(1) Using an ohmmeter, check that there is continuity between terminal 50 and C.
If there is no continuity, replace the starter magnetic switch assembly.





(b) Check the holding coil continuity.
(1) Using an ohmmeter, check that there is continuity between terminals 50 and switch body.
If there is no continuity, replace the starter magnetic switch assembly.