1Kd-Ftv Starting. Starter (For Bosch Made) Inspection

Engine Hybrid System. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

1Kd-Ftv Starting. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

INSPECT STARTER ASSEMBLY
INSPECT STARTER ARMATURE ASSEMBLY
INSPECT STARTER BRUSH HOLDER ASSEMBLY
INSPECT STARTER CLUTCH SUB-ASSEMBLY
INSPECT MAGNET STARTER SWITCH ASSEMBLY

Starter (For Bosch Made) -- Inspection

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 became hot and cause injury.

NOTICE:

These tests must be performed within 3 to 5 seconds to prevent the coil from burning out.

Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Starting.Starting System.Starter (For Bosch Made) Inspection

Text in Illustration
*1	Terminal 30	*2	Terminal 50
*3	Terminal C	-	-

Perform pull-in test.
1. Remove the nut, and then disconnect the field coil core from terminal C.
2. Connect the battery to the magnet starter switch as shown in the illustration. Then check that the clutch pinion gear moves outward.
  
  Text in Illustration
  *a
  Operation
  -
  -
  If the clutch pinion gear does not move, replace the magnet starter switch assembly.

Text in Illustration
*a	Operation	-	-

Perform holding test.
1. When the battery is connected as above with the clutch pinion gear out, disconnect the negative (-) lead from terminal C. Check that the pinion gear remains out.
  
  Text in Illustration
  *1
  Terminal C
  -
  -
  *a
  Disconnect
  -
  -
  If the clutch pinion gear returns inward, replace the magnet starter switch assembly.

Text in Illustration
*1	Terminal C	-	-
*a	Disconnect	-	-

Inspect clutch pinion gear return.
1. Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear returns inward.
  
  Text in Illustration
  *a
  Disconnect
  *b
  Operation
  If the clutch pinion gear does not return inward, replace the magnet starter switch assembly.

Text in Illustration
*a	Disconnect	*b	Operation

Perform operation test without load.
1. Connect the field coil lead wire to terminal C with the nut.
  Torque:
  8.0 N*m{82 kgf*cm, 71 in.*lbf}
2. Mount the starter in a vise between aluminum plates.
3. Connect the battery and ammeter to the starter as shown in the illustration.
4. Check that the starter rotates smoothly and steadily while the pinion gear is moving outward. Then measure the current.
  Standard current:
  123 A or less at 11.5 V
  
  Text in Illustration
  *1
  Terminal 30
  *2
  Terminal 50
  *a
  Connect
  -
  -
  If the result is not as specified, replace the starter assembly.

2. INSPECT STARTER ARMATURE ASSEMBLY

Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

Measure the resistance.
1. Measure the resistance between the segments of the commutator.
  Standard resistance:
  Below 1.7 Ω
  If the result is not as specified, replace the armature assembly.
2. Measure the resistance between a segment of the commutator and armature coil core.
  Standard resistance:
  10 kΩ or higher
  If the result is not as specified, replace the armature assembly.

Inspect the commutator circle runout.
1. Place the commutator on V-blocks.
2. Using a dial indicator, measure the circle runout.
  Standard runout:
  0.02 mm (0.000787 in.)
  Maximum runout:
  0.04 mm (0.00157 in.)
  If the runout is more than the maximum, replace the armature assembly.

Using a vernier caliper, measure the commutator diameter.
Standard diameter:
32.2 mm (1.278 in.)
Minimum diameter:
31.1 mm (1.235 in.)
If the diameter is less than the minimum, replace the armature assembly.

Using a vernier caliper, measure the undercut depth of the commutator.
Standard depth:
0.9 mm (0.0354 in.)
Minimum depth:
0.4 mm (0.0157 in.)
If the depth is less than the minimum, replace the armature assembly.

3. INSPECT STARTER BRUSH HOLDER ASSEMBLY

Using a vernier caliper, measure the brush length.
Standard length:
14.0 mm (0.556 in.)
Minimum length:
9.0 mm (0.354 in.)
If the length is less than the minimum, replace the starter brush holder assembly.

Check the brush holder.
1. Measure the resistance between the brushes.
  Standard resistance:
  Tester Connection
  Specified Condition
  A - B
  10 kΩ or higher
  A - C
  10 kΩ or higher
  A - D
  Below 1 Ω
  B - C
  Below 1 Ω
  B - D
  10 kΩ or higher
  C - D
  10 kΩ or higher
  If the result is not as specified, replace the starter brush holder assembly.

4. INSPECT STARTER CLUTCH SUB-ASSEMBLY

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
*a
Free
*b
Lock
If the result is not as specified, replace the starter clutch sub-assembly.

Text in Illustration
*a	Free
*b	Lock

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.

5. INSPECT MAGNET STARTER SWITCH ASSEMBLY

Check the plunger.
Text in Illustration
*1
Switch Body
*2
Spring
*3
Plunger
1. Install the plunger and spring onto the switch body.
2. Push in the plunger and check that it returns quickly to its original position.
  If the result is not as specified, replace the magnet starter switch assemby.

Text in Illustration
*1	Switch Body
*2	Spring
*3	Plunger

Check if the pull-in coil has an open circuit.
1. Measure the resistance between terminal 50 and terminal C.
  Standard resistance:
  Below 1 Ω
  If the result is not as specified, replace the magnet starter switch assembly.

Check if the hold-in coil has an open circuit.
1. Measure the resistance between terminal 50 and the switch body.
  Standard resistance:
  Below 2 Ω
  Text in Illustration
  *1
  Terminal 50
  If the result is not as specified, replace the magnet starter switch.

Tester Connection	Specified Condition
A - B	10 kΩ or higher
A - C	10 kΩ or higher
A - D	Below 1 Ω
B - C	Below 1 Ω
B - D	10 kΩ or higher
C - D	10 kΩ or higher