Toyota Tacoma (2015-2018) Service Manual: Inspection

Toyota Tacoma (2015-2018) Service Manual / 2gr-fks Starting / Starter / Inspection

INSPECTION

PROCEDURE

1. INSPECT MAGNET STARTER SWITCH ASSEMBLY

(a) Inspect the pull-in coil.

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

Text in Illustration

*a	Terminal 50
*b	Terminal C

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.

(b) Inspect the holding coil.

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

Text in Illustration

*a	Terminal 50
*b	Switch Body

Standard Resistance:

Tester Connection	Condition	Specified Condition
Terminal 50 - Switch body	Always	Below 2 Ω

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

2. INSPECT BRUSH

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

Text in Illustration

*a	Brush Holder Side
*b	Starter Yoke Side
*c	Length

Standard length:

15.5 mm (0.610 in.)

Minimum length:

8.5 mm (0.335 in.)

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

3. INSPECT STARTER BRUSH HOLDER ASSEMBLY

(a) Check the brush spring load.

(1) Take a pull scale reading immediately after the brush spring separates from the brush.

Text in Illustration

*a	Brush
*b	Brush Spring

Standard spring load:

17.6 to 23.5 N (1.8 to 2.4 kgf, 4.0 to 5.3 lbf)

Minimum spring load:

11.8 N (1 kgf, 2.7 lbf)

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

(b) Inspect the insulation.

(1) 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.

4. INSPECT STARTER YOKE ASSEMBLY

(a) Inspect the field coil for an open circuit.

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

Standard Resistance:

Tester Connection	Condition	Specified Condition
Lead wire - Brush	Always	Below 1 Ω

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

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

Standard Resistance:

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

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

5. INSPECT STARTER ARMATURE ASSEMBLY

(a) Check the commutator for dirt and/or burns on the surface.

If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe. If necessary, replace the starter armature assembly.

(b) Inspect the commutator for an open circuit.

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

Text in Illustration

Segment

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.

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

Text in Illustration

*a	Segment
*b	Coil Core

Standard Resistance:

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

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

(d) Check the commutator circle runout.

(1) Place the bearing of armature on V-blocks.

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

Maximum runout:

0.05 mm (0.00197 in.)

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

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

Standard diameter:

30.0 mm (1.18 in.)

Minimum diameter:

29.0 mm (1.14 in.)

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

(f) Using a vernier caliper, measure the undercut depth of the commutator.

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, replace the starter armature assembly.

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.

Text in Illustration

	Free
	Lock

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

(b) Turn the pinion gear by hand while applying inward force and check the movement of the bearing.

If resistance is felt or the bearing sticks, replace the starter clutch sub-assembly.

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