Starter Overhaul Test

- 23 -
Test
Components

To check the starter operation, apply voltage to the battery directly
and check the starter functions individually.
1. Pull-In Test
2. Hold-In Test
3. Check Pinion Gear Clearance
4. Pinion Return Test
5. No-Load Test

NOTICE:
Since applying the battery voltage to the starter for a long time
will burn the coils, limit each test to 3 to 5 seconds.
Also perform the above tests in succession since they are
intended to check the successive operation of the starter.
Understand the procedure well before beginning inspection.

1. Pull-In Test
2. Hold-In Test
3. Check Pinion Gear Clearance
4. Pinion Return Test
5. No-Load Test

NOTICE:
Since applying the battery voltage to the starter for a long time
will burn the coils, limit each test to 3 to 5 seconds.
Also perform the above tests in succession since they are
intended to check the successive operation of the starter.
Understand the procedure well before beginning inspection.

1. Pull-In Test
2. Hold-In Test
3. Check Pinion Gear Clearance
4. Pinion Return Test
5. No-Load Test

NOTICE:
Since applying the battery voltage to the starter for a long time
will burn the coils, limit each test to 3 to 5 seconds.
Also perform the above tests in succession since they are
intended to check the successive operation of the starter.
Understand the procedure well before beginning inspection.

Starter Overhaul Test
- 24 -

1. Pull-In Test
2. Hold-In Test
3. Check Pinion Gear Clearance
4. Pinion Return Test
5. No-Load Test

NOTICE:
Since applying the battery voltage to the starter for a long time
will burn the coils, limit each test to 3 to 5 seconds.
Also perform the above tests in succession since they are
intended to check the successive operation of the starter.
Understand the procedure well before beginning inspection.

1. Pull-In Test
2. Hold-In Test
3. Check Pinion Gear Clearance
4. Pinion Return Test
5. No-Load Test

NOTICE:
Since applying the battery voltage to the starter for a long time
will burn the coils, limit each test to 3 to 5 seconds.
Also perform the above tests in succession since they are
intended to check the successive operation of the starter.
Understand the procedure well before beginning inspection.
(1/1)



Starter body

Terminal 50

Terminal C

Field coil lead wire

Terminal 30


Test lead A

Hold-in coil

Pull-in coil

Pinion gear

Pull-in Test

Check that the magnet starter switch functions normally.
1. Pull-in test
(1) Disconnect the field coil lead wire from the terminal C to
prevent the starter from turning.
(2) Connect the battery positive (+) terminal to terminal 50.
(3) Connect the battery negative (-) terminal to the starter body
and to the terminal C (test lead A), and check if the pinion
gear comes out.

HINT:
The ignition switch creates a state of START position
artificially. Then make the current flow to the pull-in coil and
hold-in coil and check that the pinion gear pops out.
If the pinion gear does not pop out, replace the magnet starter
switch assembly.
(1/1)


Starter Overhaul Test
- 25 -


Starter body

Terminal 50

Terminal C

Field coil lead wire

Terminal 30


Test lead A

Hold-in coil

Pull-in coil

Pinion gear

Hold-in Test

Check that the holding coil functions normally.
1. Hold-in test
(1) Disconnect test lead A from terminal C with the pinion gear
out after the pull-in test.
(2) Check if the pinion gear remains out.

HINT:
Disconnecting test lead A, which connects the battery
negative terminal and the terminal C, from the terminal C cuts
off the current into the pull-in coil and makes the current flow
only into the hold-in coil.
If the pinion gear does not remain out, replace the magnet
starter switch assembly.
(1/1)


Check Pinion Gear Clearance

Check how much the pinion gear comes out.
1. Check pinion gear clearance
(1) With the state of hold-in test, measure the clearance between
the pinion gear end and stop collar.

SERVICE HINT:
Measuring
(See Basic Skills of Basics of Overhaul on PDF page 53-55)

HINT:
If the clearance is outside of the specified value range, replace
the magnet starter switch assembly.
(1/1)

Starter Overhaul Test
- 26 -

Starter body

Test lead A
Terminal 50 Hold-in coil
Terminal C Pull-in coil
Field coil lead wire Pinion gear
Terminal 30
Pinion Return Test

Check that the pinion gear returns to its original position.
1. Pinion return test
(1) With the pinion gear out after the hold-in test, disconnect the
grounding wire from the starter body.
(2) Make sure that the pinion gear returns to its original position.

HINT:
Artificially creating the state in which the ignition switch
returns from the START position to the ON position will lead
to the state in which the electricity supply to the hold-in coil is
stopped.
Replace the magnet starter switch assembly if the pinion gear
does not return to its original position.
(1/1)


Starter body

Terminal C

Terminal 50

Terminal 30
No-Load Test

Check the state of the contact point of the magnet starter switch
and the contact between the commutator and the brush.

1. No-load test
(1) Hold the starter in a vise wedged between aluminium plates
or a cloth.
(2) Connect the removed field coil lead wire to terminal C.
(3) Connect the battery positive (+) terminal to terminal 30 and
terminal 50.
(4) Connect an electrical tester between the battery positive (+)
terminal and terminal 30.
(5) Connect the battery negative (-) terminal to the starter body
and turn the starter.
(1/2)


(6) Measure the current flowing into the starter.
Specified current:
Less than 50 A at 11V
In case of COROLLA NZE 12# series

NOTICE:
Since applying the battery voltage to the starter for a long time
will burn the coils, limit this test to 3 to 5 seconds.
The current flowing in no-load test differs depending on the
starter motors, but 200 to 300A current flows into some
motors. See the Repair Manual for the amperage in advance
and be sure to use the appropriate amperage meter and lead
wire with sufficient capacity.

Starter body

Terminal C
Terminal 50

Terminal 30
(2/2)