TOYOTA STARTING SYSTEMS

ASSIGNMENT NAME:

1. List the two staring system circuits.

The starting system has two separate electrical circuits ... a control circuit and a motor circuit.

2. List the components that make up the “control circuit”.

A starter relay, a neutral start switch, a clutch switch, IGSW.

3. List the components that make up the “motor circuit”.

Starter motor, Magnetic Switch.

4. Explain in detail how a “Conventional Starter” differs from that of a “Gear Reduction
Starter”.

CONVENTIONAL STARTER MOTOR

The pinion gear is on the same shaft as the motor armature and rotates at the same
speed. A plunger in the magnetic switch (solenoid) is connected to a shift lever. When
activated by the plunger, the shift lever pushes the pinion gear and causes it to mesh with
the flywheel ring gear. When the engine starts, an over-running clutch disengages the
pinion gear to prevent engine torque from ruining the starting motor.

This type of starter was used on most 1975 and older Toyota vehicles. It is currently used
on certain Tercel models. Typical output ratings are 0.8, 0.9, and 1.0KW. In most cases,
replacement starters for these older motors are gear-reduction motors.

GEAR-REDUCTION STARTER MOTOR

This type of starter has a compact, high-speed motor and a set of reduction gears. While
the motor is smaller and weighs less than conventional starting motors, it operates at
higher speed. The reduction gears transfer this torque to the pinion gear at 1/4 to 1/3 the
motor speed. The pinion gear still rotates faster than the gear on a conventional starter and
with much greater torque (cranking power).

The reduction gear is mounted on the same shaft as the pinion gear. And, unlike in the
conventional starter, the magnetic switch plunger acts directly on the pinion gear (not
through a drive lever) to push the gear into mesh with the ring gear.

This type of starter was first used on the 1973 Corona MKII with the 4M, six cylinder
engine. It is now used on most 1975 and newer Toyotas.

Ratings range from 0.8KW on most Tercels and some older models to as high as 2.5KW
on the diesel Corolla, Camry and Truck. The cold-weather package calls for a 1.4KW or
1.6KW starter, while a 1.0KW starter is common on other models.

5. Explain why an “overrunning clutch” is needed and how it works.

Both types of starter motors used on Toyota starting systems have a one-way clutch, or over-
running clutch. This clutch prevents damage to the starter motor once the engine has been
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started. It does so, by disengaging its housing (which rotates with the motor armature) from an
inner race which is combined with the pinion gear. Spring loaded wedged rollers are used.

Without an over-running clutch, the starter motor would be quickly destroyed if engine torque
was transferred through the pinion gear to the armature

6. Explain how the “starter drive pinion” engages (pushed out) with the ring gear when
the ignition key is turned to the “Start” position.

IGNITION SWITCH IN "ST"

• Current flows from the battery through terminal "50" to the hold-in and pull-in coils. Then,
from the pull-in coil, current flows through terminal "C" to the field coils and armature coils.

• Voltage drop across the pull-in coil limits the current to the motor, keeping its speed low.

• The magnetic switch plunger pushes the pinion gear to mesh with the ring gear.

• he screw and low motor speed help the gears mesh smoothly.

7. List and describe the five items included in a “Visual Inspection”.

• SAFETY FIRST: The same safety considerations used in checking the battery apply here.
Remove rings, wristwatch, other jewelry that might contact battery terminals. Wear safety
glasses and protective clothing. Be careful not to spill electrolyte and know what to do if
electrolyte gets in your eyes, on your skin or clothing, or on the car's finish. Write down
programmed settings on electronic components. Avoid causing sparks.

• STARTING PERFORMANCE: Check the starting performance. Problem symptoms, possible

causes, and needed actions are shown in the chart on the previous page.

• BATTERY CHECKS: Inspect the battery for corrosion, loose connections. Check the electrolyte
level, condition of the plates and separators, and state of charge (specific gravity or open-circuit
voltage). Load test the battery. It must be capable of providing at least 9.6 volts during cranking.

• STARTER CABLES: Check the cable condition and connections. Insulation should not be worn
or damaged. Connections should be clean and tight.

• STARTER CONTROL CIRCUIT: Check the operation of the ignition switch. Current should be
supplied to the magnetic switch when the ignition is "on" and the clutch switch or neutral start
switch is closed. Faulty parts that prevent cranking can be located using a remote-control starter
switch and a jumper wire. Use the "split half" diagnosis method. Ohmmeter checks can also
identify component problems.

8. Explain in detail the steps taken in order to perform a “Current Draw Test”.

The following steps outline a typical procedure for performing a current draw test on a starting
system:

a. This test should be made only with a serviceable battery. The specific gravity readings at
800˚F should average at least 1. 190 (50% charged). Charge the battery, if necessary.

b. Prepare the tester:

• Rotate the Load Increase control to OFF.

 TOYOTA STARTING SYSTEMS
• Check each meter's mechanical zero. Adjust, if necessary.

• Connect the tester Load Leads to the battery terminals; RED to positive, BLACK to negative.

NOTE: Battery open-circuit voltage should be at least 12.2 volts (50% charged). If not, the
battery requires charging.

• Set Volt Selector to INT 18V. Tester voltmeter should indicate battery open-circuit voltage.

• Set Test Selector to #2 CHARGING.

• Adjust ammeter to read ZERO using the electrical Zero Adjust control.

c. Connect the clamp-on Amps Pickup around the battery ground cable or cables.

d. Make sure all lights and accessories are off and vehicle doors are closed.

e. Set the Test Selector switch to #1 STARTING.

f. Disable the ignition so the engine does not start during testing.

g. Crank the engine, while observing the tester ammeter and voltmeter.

• Cranking speed should be normal (200-250 rpm).

• Current draw should not exceed the maximum specified.

• Cranking voltage should be at or above the minimum specified.

h. Restore the engine to starting condition and remove tester leads.

9. Explain the procedure and the need for a voltage drop test of the “Motor Circuit”

Voltage-drop testing can detect excessive resistance in the starting system. High resistance in
the starter motor circuit (power side or ground side) will reduce current to the starting motor. This
can cause slow cranking speed and hard starting. High resistance in the starter control circuit
will reduce current to the magnetic switch. This can cause improper operation or no operation at
all.

The following steps outline a typical procedure for performing voltage-drop tests on the starting
system:

Motor Circuit (insulated Side)

a. If using the Sun VAT-40, set the Volt Selector to EXT 3V. For other voltmeters, use a low
scale.

b. Connect the voltmeter leads ... RED to the battery positive (+) terminal, BLACK to terminal "C"
on the starter motor magnetic switch.

c. Disable the ignition so the engine cannot start during testing.

NOTE: On models with the Integrated Ignition Assembly, disconnect the "IIA" plug. On others,
disconnect the power plug to the remote igniter assembly (black-orange wire).

d. Crank the engine and observe the voltmeter. Less than 0.5 volt indicates acceptable
resistance. More than 0.5 volt indicates excessive resistance. This could be caused by a
 TOYOTA STARTING SYSTEMS
damaged cable, poor connections, or a defective magnetic switch.

e. If excessive resistance is indicated, locate the cause. Acceptable voltage drops are 0.3 volt
across the magnetic switch, 0.2 volts for the cable, and zero volts for the cable connection.
Repair or replace components, as needed.

Motor Circuit (Ground Side)

a. Connect the voltmeter leads ... RED to the starter motor housing, BLACK to the battery
ground (-) terminal.

b. Crank the engine and observe the voltmeter. Less than 0.2 volt indicates acceptable
resistance. More than 0.2 volt indicates excessive resistance. This could be caused by a loose
motor mount, a bad battery ground, or a loose connection. Repair or replace components as
necessary. Make sure engine-to-body ground straps are secure.

Starting System Operation

- IGNITION SWITCH IN "ST"

When the ignition switch is turned on in the START position, the battery current flows into the holding
coil and traction coil. Then the current flows from the traction coil to the armature through the inductor,
causing the armature to rotate at a low speed. The generation of electromagnetic force in the holding
and pulling coils magnetizes the pole core and thus the piston of the magnetic switch is pulled into the
pole core of the electromagnet. Thanks to this pull, the starter drive gear is easily pushed out and
meshes with the flywheel gear ring and the contact disc will turn on the main switch.
 TOYOTA STARTING SYSTEMS

- PINION AND RING GEARS ENGAGED

When the main switch is turned on, no current flows through the coil and the coil receives current
directly from the battery. The armature coil then begins to rotate at high speed and the motor is started.
At this point the piston is kept in position only by the electromagnetic force of the retaining coil because
there is no electromagnetic force running through the suction coil.

- IGNITION SWITCH IN "ON"

When the ignition switch is rotated from the START position to the ON position, current flows from the
main switch side to the holding coil through the pull coil. In this position, the electromagnetic force
created by the pulling coil and the retaining coil cancels each other out, so the piston can no longer be
held. Therefore, the piston is pulled back by the return spring and the main switch is disconnected,
causing the starter to stop.