2ZR-FE STARTING STARTER INSPECTION

Hide Display 28100 1.INSPECT STARTER ASSEMBLY

CAUTION:: As a large electric current passes through the cable during this inspection, a thick cable must be used. If not, the cable may become hot and cause injury.

NOTICE:: Perform each of the following tests within 3 to 5 seconds to prevent the coil from burning out.

a.

Perform a pull-in test.

i.

Remove the nut, and disconnect the field coil lead wire from terminal C.

ii.

0.99,0.792 1.198,0.792 1.198,0.792 1.406,1.26 false 2.427,1.635 1.948,2.604 1.948,2.604 1.635,2.604 true 2.677,1.469 2.75,1.052 2.75,1.052 2.927,1.052 false 0.781,0.698 1.094,0.854 0.313,0.156 10 false *a 1.438,2.51 1.75,2.667 0.313,0.156 10 false *b 3,0.958 3.313,1.115 0.313,0.156 10 false *c

*a	Starter Body
*b	Terminal C
*c	Terminal 50

Connect a battery to the magnet starter switch assembly as shown in the illustration. Check that the clutch pinion gear moves outward.

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

b.

Perform a hold-in test.

i.

2.427,1.635 1.938,2.542 1.938,2.542 1.667,2.542 true 1.396,1.281 1.104,0.74 1.104,0.74 0.854,0.74 false 2.677,1.469 2.823,0.969 2.823,0.969 3.052,0.969 false 0.667,0.646 0.896,0.875 0.229,0.229 10 false *a 3.115,0.865 3.427,1.021 0.313,0.156 10 false *c 1.479,2.469 1.719,2.698 0.24,0.229 10 false *b

*a	Starter Body
*b	Terminal C
*c	Terminal 50

While maintaining the battery connections of the pull-in test, disconnect the negative (-) lead from terminal C. Check that the clutch pinion gear does not return inward.

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

c.

Perform a return test.

i.

2.406,1.635 1.938,2.688 1.938,2.688 1.688,2.688 false 1.396,1.281 1.031,0.719 1.031,0.719 0.76,0.719 false 2.688,1.479 2.802,0.969 2.802,0.969 3.031,0.969 false 0.573,0.604 0.76,0.823 0.188,0.219 10 false *a 3.094,0.875 3.427,1.094 0.333,0.219 10 false *c 1.521,2.604 1.719,2.844 0.198,0.24 10 false *b

*a	Starter Body
*b	Terminal C
*c	Terminal 50

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 a no-load performance test.

i.

Connect the field coil lead wire to terminal C with the nut.

Torque:: 9.8 N*m (100 kgf*cm, 87 in.*lbf)

ii.

Hold the starter assembly in a vise between aluminum plates.

NOTICE:: Ensure that the starter assembly is secured in the vise to prevent it from falling out.

iii.

2.448,1.563 1.927,2.781 1.927,2.781 1.625,2.781 true 1.448,1.219 1.073,0.635 1.073,0.635 0.781,0.635 false 2.563,1.49 2.74,0.906 2.74,0.906 2.917,0.906 false 0.594,0.531 0.938,0.688 0.344,0.156 10 false *a 1.427,2.688 1.635,2.917 0.208,0.229 10 false *b 2.958,0.802 3.323,0.948 0.365,0.146 10 false *c

*a	Starter Body
*b	Terminal 50
*c	Terminal 30

Connect the battery and an ammeter to the starter assembly as shown in the illustration.

NOTICE:: Do not allow any lead to get caught as the clutch pinion gear operates.

iv.

Check that the starter assembly operates smoothly and steadily while the clutch pinion gear is moving outward.

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

Standard Current:

Tester Connection	Condition	Specified Condition
Battery positive (+) terminal - Terminal 30 - Terminal 50	11.5 V	Below 90 A

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

Hide Display 28160 2.INSPECT STARTER ARMATURE ASSEMBLY

a.

2.26,1.167 2.885,1.094 2.885,1.094 2.354,0.958 false 2.917,1.021 3.229,1.219 0.313,0.198 10 false *a

*a

Segment

Check the commutator for an open circuit.

i.

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

Standard Resistance:

Tester Connection	Condition	Specified Condition
Segment - Segment	Always	Below 1 Ω

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

b.

0.792,1.302 1.073,1.302 1.073,1.302 1.604,0.896 false 2.302,1.198 2.615,0.542 2.615,0.542 2.833,0.542 true 2.885,0.458 3.198,0.656 0.313,0.198 10 false *a 0.563,1.219 0.875,1.417 0.313,0.198 10 false *b

*a	Segment
*b	Starter Armature Core

Check the commutator for a short circuit.

i.

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

Standard Resistance:

Tester Connection	Condition	Specified Condition
Segment - Starter armature core	Always	10 kΩ or higher

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

c.

Check the commutator appearance.

If the surface is dirty or burnt, restore it with sandpaper (400-grit) or on a lathe.

d.

1.948,1.396 0.313,1.771 0.313,1.771 0.927,0.875 true 0.115,1.667 0.427,1.865 0.313,0.198 10 false *a

*a	Armature Shaft

Check the commutator for runout.

i.

Place the armature shaft on V-blocks.

ii.

Using a dial indicator, measure the 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:: 28 mm (1.1024 in.)

Minimum Diameter:: 27 mm (1.0630 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:: 0.6 mm (0.0236 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.

Hide Display 28120 3.INSPECT STARTER YOKE ASSEMBLY

a.

Check the starter yoke assembly resistance.

i.

1.656,0.521 1.969,0.677 0.313,0.156 10 false *a 0.896,0.958 1.208,1.115 0.313,0.156 10 false *b

*a	Brush Lead Wire
*b	Field Coil Lead Wire

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

Standard Resistance:

Tester Connection	Condition	Specified Condition
Brush lead wire - Field coil lead wire	Always	Below 1 Ω

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

ii.

1.635,0.427 1.948,0.583 0.313,0.156 10 false *a 1.219,1.333 1.531,1.49 0.313,0.156 10 false *b

*a	Brush Lead Wire
*b	Starter Yoke Assembly Body

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

Standard Resistance:

Tester Connection	Condition	Specified Condition
Brush lead wire - Starter yoke assembly body	Always	10 kΩ or higher

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

Hide Display 28140 4.INSPECT STARTER BRUSH HOLDER ASSEMBLY

a.

Check the brush length.

i.

Using a vernier caliper, measure the brush length.

Standard Length:: 14 mm (0.551 in.)

Minimum Length:: 9 mm (0.354 in.)

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

b.

1.948,0.667 2.635,0.667 false 0.969,1.271 0.458,1.271 false 1.031,0.563 0.573,0.313 false 1.948,1.313 2.24,1.844 true 2.302,1.75 2.542,1.917 0.24,0.167 10 false (+) 0.375,0.219 0.615,0.385 0.24,0.167 10 false (+) 0.281,1.177 0.521,1.344 0.24,0.167 10 false (-) 2.698,0.563 2.938,0.729 0.24,0.167 10 false (-)

Check the brush holder resistance.

i.

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

Standard Resistance:

Tester Connection	Condition	Specified Condition
Positive (+) brush holder - Negative (-) brush holder	Always	10 kΩ or higher

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

c.

Check the brush spring load.

i.

Using a spring scale, measure the spring load at the moment the brush spring separates from the brush.

Standard Spring Load:: 13.7 to 17.6 N (1.40 to 1.80 kgf, 3.08 to 3.96 lbf)

Minimum Spring Load:: 8.8 N (0.90 kgf, 1.98 lbf)

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

Hide Display 28011 5.INSPECT STARTER CLUTCH SUB-ASSEMBLY

1.385,0.313 1.698,0.469 0.313,0.156 10 *a 1.417,1.615 1.729,1.771 0.313,0.156 10 *b

*a	Free
*b	Lock

a.

Check the clutch pinion gear.

i.

While holding the starter clutch sub-assembly, 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.

If the clutch pinion gear does not operate as specified, replace the starter clutch sub-assembly.

Hide Display 28150 6.INSPECT MAGNET STARTER SWITCH ASSEMBLY

a.

Check the plunger.

i.

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

NOTICE:: To avoid damaging the inside of the magnet starter switch assembly, do not release the plunger quickly.

If necessary, replace the magnet starter switch assembly.

b.

1.688,1.448 2,1.854 2,1.854 2.323,1.854 false 1.583,1.094 1.01,0.594 1.01,0.594 0.729,0.594 false 2.375,1.76 2.74,1.938 0.365,0.177 10 false *b 0.521,0.5 0.833,0.656 0.313,0.156 10 false *a

*a	Terminal 50
*b	Terminal C

Check the pull-in coil for an open circuit.

i.

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

Standard Resistance:

Tester Connection	Condition	Specified Condition
Terminal 50 - Terminal C	Always	Below 1 Ω

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

c.

1.958,1.396 1.958,1.594 false 1.323,1.094 0.792,0.563 0.792,0.563 0.531,0.563 false 0.333,0.469 0.677,0.615 0.344,0.146 10 false *a 1.875,1.615 2.219,1.781 0.344,0.167 10 false *b

*a	Terminal 50
*b	Magnet Starter Switch Assembly Body

Check the holding coil for an open circuit.

i.

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

Standard Resistance:

Tester Connection	Condition	Specified Condition
Terminal 50 - Magnet starter switch assembly body	Always	Below 2 Ω

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

PROCEDURE